Omega V1384.81/2--10Operating instructions

Volute casing pumpwith radial impeller

Pump set

Vertical installation – DBDKDJ

These operating instructions contain fundamental information and precautionary notes.Please read the manual thoroughly prior to installation of unit, electrical connection andcommissioning. It is imperative to comply with all other operating instructions referring tocomponents of individual units.

Any work on the unit must only be carried out with the electrical connections (incl. control cable)disconnected (or unplugged). Make sure that the pump set cannot be switched on accidentally.

Ident--No.: 01 059 621

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For usage in hazardous locationsrefer to supplementary operatinginstructions 1387.81.

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Contents Page

1 General 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Safety 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1 Marking of Instructions in the Manual 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2 Personnel Qualification and Training 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3 Non--Compliance with Safety Instructions 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4 Safety Awareness 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5 Safety Instructions for the Operator / User 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6 Safety Instructions for Maintenance, Inspection and Installation Work 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7 Unauthorized Modification and Manufacture of Spare Parts 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.8 Unauthorized Modes of Operation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Transport and Interim Storage 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1 Transport 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2 Intermediate Storage / Preservation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Description of the Product and Accessories 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1 Technical Specification 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2 Designation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3 Design Details 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.4 Types of Installation 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5 Accessories (optional) 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.6 Dimensions and Weights 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Installation at Site 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1 Safety Regulations 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.2 Checks to Be Carried out Prior to Installation 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.3 Installing the Pump / Unit 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.4 Connecting the Piping 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.5 Final Check 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 Commissioning, Start--up / Shut down 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1 Commissioning 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.2 Shaft Seal 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.3 Venting 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.4 Commissioning 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.5 Shutdown / Storage / Preservation 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.6 Returning to Service after Storage 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 Maintenance / Repair 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.1 General Instructions 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.2 Maintenance / Inspection 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.3 Dismantling 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.4 Reassembly 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.5 Instructions for Replacing Subassemblies 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.6 Monitoring schedule 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 Special Instructions for Subassemblies (Shaft Seal Variants) 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.1 Gland packing 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.2 Mechanical Seal Variants (Mech. Seal Size / Pump Size Combinations) 18. . . . . . . . . . . . . . . . . . . . . . . . . . .

9 Spare Parts 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 Forces and Moments 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 Trouble--Shooting 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.1 General 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.2 Trouble--shooting Table 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 Routine Maintenance and Inspection Intervals 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 Appendix 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1 GeneralThis KSB pump has been developed in accordance withstate--of--the--art technology; it is manufactured withutmost care and subject to continuous quality control.These operating instructions are intended to facilitatefamiliarization with the pump and its designated use.The manual contains important information for reliable, properand efficient operation. Compliance with the operatinginstructions is of vital importance to ensure reliability and a longservice life of the pump and to avoid any risks.These operating instructions do not take into account localregulations; the operatormust ensure that such regulationsarestrictly observed by all, including the personnel called in forinstallation.This pump / unit must not be operated beyond the limit valuesspecified in the technical documentation for the mediumhandled, capacity, speed, density, pressure, temperature andmotor rating.Makesure that operation is in accordancewith theinstructions laid down in this manual or in the contractdocumentation.The name plate indicates the type series / size, main operatingdata and works / series number; please quote this informationin all queries, repeat orders and particularly when orderingspare parts.If youneedanyadditional informationor instructionsexceedingthe scope of this manual or in case of damage please contactKSB’s nearest customer service centre.

2 SafetyThese operating instructions contain fundamental informationwhich must be complied with during installation, operation andmaintenance. Therefore this operating manual must be readand understood both by the installing personnel and theresponsible trained personnel / operators prior to installationand commissioning, and it must always be kept close to thelocation of operation of the machine / unit for easy access.Not only must the general safety instructions laid down in thischapter on ”Safety” be complied with, but also the safetyinstructions outlined under specific headings.

2.1 Marking of Instructions in the ManualThe safety instructions contained in this manual whosenon--observancemight cause hazards to persons are speciallymarked with the general hazard sign, namely

safety sign in accordance with DIN 4844 -- W9.The electrical danger warning sign is

safety sign in accordance with DIN 4844 -- W8.

The word

Caution

is used to introducesafety instructionswhosenon--observancemay lead to damage to the machine and its functions.Instructions attached directly to the machine, e.g.-- arrow indicating the direction of rotation-- markings for fluid connections

must always be complied with and be kept in perfectly legiblecondition at all times.

2.2 Personnel Qualification and TrainingAll personnel involved in the operation, maintenance,inspectionand installationof themachinemustbe fullyqualifiedto carry out the work involved.Personnel responsibilities, competence and supervision mustbe clearly defined by the operator. If the personnel in questionis not already in possession of the requisite know--how,appropriate training and instruction must be provided. Ifrequired, the operator may commission the manufacturer /supplier to take care of such training. In addition, the operatoris responsible for ensuring that the contents of the operatinginstructions are fully understood by the responsible personnel.

2.3 Non--Compliance with Safety InstructionsNon--compliance with safety instructions can jeopardize thesafety of personnel, the environment and the machine itself.Non--compliance with these safety instructions will also lead toforfeiture of any and all rights to claims for damages.In particular, non--compliance can, for example, result in:-- failure of important machine / unit functions-- failure of prescribed maintenance and servicing practices-- hazard to persons by electrical, mechanical and chemical

effects-- hazard to the environment due to leakage of hazardous

substances

2.4 Safety AwarenessIt is imperative to comply with the safety instructions containedin this manual, the relevant national health and safetyregulationsand theoperator’sown internalwork, operationandsafety regulations.

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2.5 Safety Instructions for the Operator / User-- Any hot or cold components that could pose a hazard must

be equipped with a guard by the operator.-- Guards which are fitted to prevent accidental contact with

moving parts (e.g. coupling)must not be removedwhilst themachine is operating.

-- Leakages (e.g. at the shaft seal) of hazardous mediahandled (e.g. explosive, toxic, hot)must be contained so asto avoid any danger to persons and the environment.Pertinent legal provisions must be adhered to.

-- Electrical hazardsmust be eliminated. (In this respect referto the relevant safety regulations applicable to differentcountries and/or the local energy supply companies.)

2.6 Safety Instructions for Maintenance,Inspection and Installation Work

The operator is responsible for ensuring that all maintenance,inspection and installation work be performed by authorized,qualified specialist personnel who are thoroughly familiar withthe manual.Work on themachinemust be carried out only during standstill.The shutdownproceduredescribed in themanual for taking themachine out of service must be adhered to without fail.Pumps or pump units handling media injurious to health mustbe decontaminated.Immediately following completion of the work, allsafety--relevant and protective devices must be re--installedand/or re--activated.Please observe all instructions set out in the chapter on”Commissioning” before returning the machine to service.

2.7 Unauthorized Modification and Manufactureof Spare Parts

Modifications or alterations of the machine are only permittedafter consultation with the manufacturer. Original spare partsandaccessoriesauthorizedby themanufacturer ensuresafety.The use of other parts can invalidate any liability of themanufacturer for consequential damage.

2.8 Unauthorized Modes of OperationThe warranty relating to the operating reliability and safety ofthe pump / unit supplied is only valid if the machine is used inaccordance with its designated use as described in section 1of these operating instructions. The limits stated in the datasheet must not be exceeded under any circumstances.

3 Transport and Interim Storage

3.1 TransportTransport of the unit requires proper preparation and handling.Always make sure that the pump or the unit remains in stableposition during transport and cannot slip out of the transportsuspension arrangement. Do not use lifting slings on the freeshaft end of the pump or on the motor eyebolt.Also make sure that the coupling guard is not damaged by thesling arrangement.

If the pump / unit slips out of the suspensionarrangement, it may cause personal injury anddamage to property.

Transport in horizontal position is recommended in all cases,since this ensures stable positioning of the unit without any riskof accident, whatever the method of transport, e.g. road, rail orship, etc.For transport purposes the unit shall be secured on suitablepallets or sleds. All loose and movable parts must be secured.

Fig. 1: Transport of pump (Fig.0) and installation type DJ

Fig. 2: Transport of motor

Themotor eyeboltsmust only be used for lifting themotor alone, never for lifting the complete unit.

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Fig. 3: Never transport the unit as shown above!

Fig. 4: Transport of the unit with motor stool,vertical installation type DB and DK

Observe angles of pull when lifting.Angle of pull > 90° not permitted.Use two separate sets of lifting slings!

Fig. 5: Pull directions (opening angle of slings)

3.2 Intermediate Storage / PreservationWhen the unit is temporarily put into storage, only the wettedlow alloy components, e.g. JL1040 (GG--25) must bepreserved. Commercially available preservatives can be usedfor this purpose. Please observe the manufacturer’sinstructions for application / removal.

4 Description of the Product andAccessories

4.1 Technical Specification

DesignThe KSB pump of the Omega V series is a vertically installed,single--stage, axially split volute casing pump withdouble--entry radial impeller. Connection flanges aremanufactured according to EN, DIN, ISO, BS or ASME, aspreferred.

Fields of applicationInwaterworks, irrigationanddrainagepumping stations, powerstations, for industrial water supply, dock installations, fireextinguishing systems, refineries, pipelines and tank farms,also for handling crude oil and refinery intermediates.

4.2 DesignationOmega V XXX XXX X

Type seriesDischarge nozzle DN mmNominal impeller dia.Impeller type (A,B,C)

4.3 Design Details

4.3.1 Pump CasingAxially split volute casing with replaceable casing wear rings.Suction and discharge nozzles in lower half of casing are at thesame level (inline version).

4.3.2 ImpellerThe double--entry radial impeller is manufactured for theoperating data provided in each case. Also with impeller wearrings, if requested.In double--entry radial impellers the axial thrust is largelybalanced.

4.3.3 Pump ShaftThe shaft is fully sealed against the liquid being pumped.Shaft--protecting sleeves are fitted in the seal area.

4.3.4 Shaft SealThe shaft seals at the drive end and non--drive end are glandpackings or mechanical seals, as requested.Due to the product--lubricated lower RESIDOR� bearing, onebottom shaft seal is omitted.

4.3.5 Bearings and LubricationThe pump is fitted on drive side with covered deep--groove ballbearings which are grease--lubricated for life.This bearing is the fixed bearing. On the non--driven end(bottom), there is the product--lubricated RESIDOR�--bearing.

Caution

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4.4 Types of InstallationThe pump is installed vertically, direct--coupled, configurationDJ, DB and DK, (see appendix).

4.5 Accessories (optional)The following accessories are available:

Configurationg

Accessories DJ DB DKMotor Y x 1)Foot / rail x ----Foot and motor stool ---- x ----Foot(incl. support foot and motor stool)

---- ---- x

Coupling and coupling guard ---- x 1)Sealing and flushing water piping x xSet of pressure gauges x xCyclone separator with pipework x xVent valve (manual or automatic) x xTemperature sensor for rollingelement bearings (PT 100)

x x

Signal transmitter for PT 100 x xDrain line x x1) included in standard scope of supply

Y special design

4.6 Dimensions and WeightsFor dimensions and weights please refer to the tables in theappendix.

5 Installation at Site

5.1 Safety RegulationsElectrical equipment operated in ”zone 1”hazardous locations must comply with the

explosion protection regulations. This is indicated on themotor rating plate.

If the equipment is installed in hazardous locations, theapplicable local explosion protection regulations and theregulations of the test certificate supplied with the equipmentand issued by the responsible approval authorities must beobserved and complied with.The test certificate must be kept close to the location ofoperation for easy access (e.g. foreman’s office).

5.2 Checks to Be Carried out Prior toInstallation

All structural work required must have been prepared inaccordance with the dimensions and loads stated in thedimension table / installation plan.The concrete foundations shall have sufficient strength(min. BN 25) to ensure safe and functional installation inaccordance with DIN 1045 or equivalent standards.Make sure that the concrete foundation has set firmly beforeplacing the unit on it. Its surface shall be truly horizontal andeven.

5.3 Installing the Pump / UnitBefore setting up the pump, check theoperating data. Ensure that the data on the

name plate matches the data in the order and the systemdata, e.g. operating voltage, frequency, pumped liquidtemperature etc.

The attachment shows the installation types DJ, DB, and DK.

The designation of parts can be taken from these drawings(part No.)

While the installation type DJ can be independent of the size ofthe pumpor themotor, the installation typesDBandDKdependon the size of the pump and the motor according to theattachment ”General Arrangement Drawing” (seecorrelation).

The site management must inform the installation personnelabout the local safety regulations prior to beginning theinstallation.

For all work subsequently described, the pump must be set upso it cannot fall over, and must be secured accordingly.The foot is to be bolted to the pump using the connectingelements supplied (see General Assembly Drawing and List ofComponents -- Annex).

Furthermore, themotor stool andpossibly thesupportsmustbeassembled. The motor stool must also be fixed with pinsbesides being bolted.

The foot must be bolted to the foundation blocks Usingadjusting screws, the pump must be aligned so that themachined motor connecting flange of the motor stool ishorizontally level in all directions, i.e. the pump stands exactlyin vertical position. Subsequently, the recesses arranged in thefoundation for the foundation blocks are grouted carefully witha concrete mixture. It must be assured that the base structureis resistant to torsion and twisting. After the concrete mixturehas set, the pump is to be connected to the piping withouttransmitting stresses or strains, and the motor installed. Theshafts must be carefully aligned with respect to each other andthe alignment of the coupling must be checked once again.

Observe operating instructions of the coupling!

Faulty alignment can lead to destruction of torque--transmittingcoupling elements and to bearing damage at the pump andmotor.According to the regulations concerning technical workingequipment, machines may only be operated with appropriatecontact protection. For this reason a coupling guard to DIN31001 must be installed prior to commissioning. Furthermore,the direction of rotation of the unit must be checked whether itcorresponds to the rotational direction arrow on the pumpcasing.Additional loads on discharge and suction nozzle, e.g. causedby:1. Weight of water--filled pipes2. Changes in length of piping due to temperature fluctuations3. Reaction forces due to unbraced expansion joints, may not

exceed the specified values * .(See section 10 -- ”Forces and Moments”).

Caution

Caution

Caution

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5.3.1 Unlocking Pump RotorPrior to commissioningorprior to thealignment of thepumpandthe motor, the pump rotor must be unlocked.Loosen and unscrew hex. head bolt (901.17) from thenon--drive end bearing cover (160).Remove plug (916 -- acc. to parts list) in the nipple joint (731)on the top casing half (105.02).Mount flushing line (719.02)according to the drawingaswell asthe operating instructions ”Barrier water/flushing line”.Secure pipe unions with LOCTITE, type 221.

Fig. 6: Locking and unlocking the pump rotor

5.3.2 Aligning the Pump / DriveImproper alignment of the unit can cause damage toboth the coupling and the unit itself!

A pump set in vertical installation types DB and DK is correctlyaligned, if a straight--edge placed axially on both couplinghalves is the samedistance fromeach shaft at all points aroundthe circumference. In addition, the distance between the twocoupling halves must remain the same all around thecircumference. Use a feeler gauge, a wedge gauge or a dialmicrometer to verify (see fig. 7).

straight edge

straight edge gauge

Fig. 7: Coupling alignment, using gauge and straight edgeSpecial instructions see appendix.

5.4 Connecting the PipingNever use the pump itself as an anchoragepoint for the piping.

Suction lift lines shall be laid with a rising slope towards thepump and suction head lines with a downward slope towardsthe pump. The pipelines shall be anchored in close proximity tothe pump and connected without transmitting any stresses orstrains. Their weightmust not exert any load on the pump.Withshort pipelines, the nominal diameters shall be at least equal tothe nominal diameters of the pump nozzles. For long pipelinesthe most economical nominal diameter has to be determinedfrom case to case.Any additional loads on the discharge and suctionnozzles, e.g. caused by:Weight of the water--filled pipes, changes in the length of pipesowing to temperature fluctuations, reaction forces due tounbraced expansion joints must not exceed the values statedin the installation plan.

An excessive, impermissible increase in the pipelineforcesmay cause leaks on the pumpwhere themediumhandled can escape into the atmosphere.

Danger of life when hot media are handled!

The flange covers on the pump suction and discharge nozzlesmust be removed prior to installation in the piping.

5.4.1 Auxiliary ConnectionsThe locations of the auxiliary connections (sealing liquid,flushing liquid, etc.) are indicated on the installation plan orpiping layout (see appendix).Please refer to the appendix for detailed assembly instructions.

These connections are required for properfunctioning of the pump and are therefore ofvital importance!

5.4.2 Coupling GuardIn compliance with the accident prevention regulationsthe pump must not be operated without a coupling

guard. If the customer specifically requests not to include acoupling guard in our delivery, then the operator must supplyone.

5.5 Final CheckRe--check the alignment as described in section 5.3.2.It must be easy to rotate the shaft by hand at the coupling.

Check the integrity and proper functioningof all connections.

Caution

Caution

Caution

Caution

Caution

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6 Commissioning,Start--up / Shut down

Compliance with the following requirements isof paramount importance. Damage resulting

from non--compliance shall not be covered by the scope ofwarranty.

6.1 CommissioningBefore starting up the pump make sure that the followingrequirements have been checked and fulfilled:

-- Has the pump been firmly bolted to the foundation?-- Have the coupling and pump unit been aligned as

specified?-- Can the unit be easily rotated by hand at the coupling?

(Carry out at least one full rotation)-- Are the pipes properly fitted?-- Has the coupling guard been fitted?-- Have staff been informed about sources of danger and

measures been taken to comply with the accidentprevention regulations?

-- Correct start--up procedure for suction lift operation.-- Is the unit protected against overload (appropriate safety

valve)?-- Have the seals been fitted as described in the appendix?-- Have any additional devices been prepared and fitted as

specified in the appendix?-- Has the pump been vented as specified in section 6.3.?

6.2 Shaft SealFor commissioning the shaft seal please refer to section 8.1 /8.2. If the pump has been out of service for a prolonged period,the measures specified in section 6.6 must be carried out.

6.3 VentingBefore start--up, the pump and the pipes must be vented andfilled with the liquid to be pumped. This is done at the vent plugon the casing (903). For suction lift operation, the pump mustalso be evacuated, i.e. a vacuum must be produced.

6.4 Commissioning

6.4.1 Checking the Direction of RotationFor trouble--free operation of the pump, thecorrect direction of rotation of the impeller is of

paramount importance. If running in the wrong direction ofrotation, the pump cannot reach its duty point; vibrations andoverheating will be the consequence. The unit or the shaft sealmight be damaged.

Correct direction of rotation:The direction of rotation must correspond to the directionindicated by the arrow on the pump. This can be verified byswitching the pump on and then off again immediately.

Before checking the direction of rotationmake sure thatthere is no foreign matter in the pump casing.

Never put your hands or any other objects into the pump!

6.4.2 Start--upDry--running will result in increased wear andmust be avoided.

If a non--return valve is not fitted at the discharge--side, closethe discharge--side gate valve.If a shut--off valve is fitted in the suction line, open it fully.All additional connections for flushing or sealing liquid etc., iffitted, must be opened fully and the flow must be checked.Switch on the motor.As soon as the pump starts to deliver -- this can be recognisedby the rising gauge pressure -- slowly open the discharge--sidegate valve fully.

Thepumpmayoperate against the closedgatevalve only during start--up and shutdown, as

otherwise inadmissible temperature rise occurs resulting indamage.

6.4.3 Pump Operating RangeThe flow rate ”Q” adjusts itself automatically to the deliveryhead according to the H--Q characteristic. The pump’spermitted operating range is subject to limits, which haveseparate causes.

1. Part load operating limit for low flow rateThis limit is indicated in theH--Qcharacteristic byQmin or by thediscontinuation of the characteristic curve.

It is not permissible to operate the pump in therange fromQ=0 toQminProlonged operation in

this range causes greatly increased mechanical loads whichthe components cannot withstand. Brief passage through thecritical range is permissible, e.g. during start--up.

2. NPSH--related limits in the part load and overload rangesThese two limits are determined by the ratio of NPSHrequired toNPSHavailable. They are determined as follows:

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The intersections of NPSHrequired and NPSHavailable areprojected onto the H--Q characteristic, where they indicate theoperating limits (refer to the diagram below). Checking of theNPSH--relatedoperating limit is not necessary for operating thepump under design conditions. If system--related changesoccur, an NPSH check must be carried out. If necessary,consult the nearest after--sales service centre.

Qmin

NPSHavailable

NPSHrequired

6.4.4 Shut downClose the shut--off element in the discharge line. If thedischarge line is equipped with a check valve, the shut--offelement may remain open, provided there is back pressure inthe line.

The shut--off element in the suction line must not beclosed when switching off the pump. Switch off themotor, making sure that the unit runs smoothly down toa standstill.

Depending on the system the pump shall have an adequateafter--run period -- with the heat source switched off -- to allowthemediumhandled to cool down sufficiently to avoid any heatbuild--up within the pump.In the case of prolonged shutdown, the shut--off element in thesuction line has to be closed.Close the auxiliary connections.In the event of frost and / or prolonged shutdowns, the pumpmust be drained or otherwise protected against freezing.

6.5 Shutdown / Storage / PreservationEach KSB pump leaves the factory carefully assembled. Ifcommissioning is to take place some time after delivery, werecommend that the following measures be taken for pumpstorage.

6.5.1 Storage of New Pumps-- New pumps are supplied by our factory duly prepared for

storage.Maximum protection for up to 12 months, if the pump isproperly stored indoors.

-- Store the pump in a dry location.

6.5.2 Measures to be Taken for Prolonged Shutdown

1. The pump remains installed; periodic check ofoperation

In order to make sure that the pump is always ready for instantstart--up and to prevent the formation of deposits within thepumpand the pump intake area, start up the pump set regularlyonce a month or once every 3 month for a short time (approx.5 minutes) during prolonged shutdown periods. Prior to anoperation check run ensure that there is sufficient liquidavailable for operating the pump.

2. The pump is removed from the pipe and storedBefore putting the pump into storage carry out all checksspecified in sections 7.1 to 7.4. Then apply appropriatepreservatives:-- Spray--coat the inside wall of the pump casing, and in

particular the impeller clearance areas,with a preservative.Spray the preservative through the suction and dischargenozzles. It is advisable to close the nozzles (for ex. withplastic caps or similar).

3. Locking the pump rotorThe shaft assembly of the vertically installed OMEGA runs ina RESIDUR� plain bearing. To transport the pump, the pumprotor must be secured against shocks which would otherwisedamage the plain bearing.

6.6 Returning to Service after StorageBefore returning the pump to service carry out all checks andmaintenance work specified in sections 5.1 and 5.2.

In addition, the instructions laid down in section 6.1”Commissioning” and section 6.4.3 ”Operatinglimits” must be observed.

Upon completion of thework, all safety--related andprotective equipment must be properly refitted and/ or reactivated before starting the pump set.

Caution

Caution

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7 Maintenance / Repair

7.1 General InstructionsThe operator is responsible for ensuring that all maintenance,inspection and installation work is carried out by authorized,duly qualified staff who are thouroughly familiar with theseoperating instructions.A regular maintenance schedule will help avoid expensiverepairs and contribute to trouble--free, reliable operation of thepump with a minimum of maintenance expenditure and work.

Work on the pump and the motor must only becarried out with the electrical connections

disconnected. Make sure that the pump set cannot beswitched on accidentally (danger of life!).

Pumps handling liquids posing health hazards must bedecontaminated. When draining the medium see to it

that there is no risk to persons or the environment. All relevantlaws must be adhered to (danger of life!).

7.2 Maintenance / Inspection

7.2.1 Supervision of OperationThe pump shall run quietly and free fromvibrations at all times.Thepumpmust neverbe

allowed to run dry.

Prolonged operation against a closed shut--off elementis not permitted in order to prevent the mediumhandled

from heating up.

At room temperatures of up to 30 °C (86 °F) the bearingtemperature shall be below 90 °C (194 °F). At higher roomtemperatures, the bearing temperature shall be below 100 °C(212 °F).

During pump operation the shut--off element in the inletline must not be closed.

Any stand--by pumps installed shall be switched on and thenimmediately off again once a week to keep them operational.Attention shall be paid to the correct functioning of the auxiliaryconnections.

If the flexible coupling elements begin to showsigns of wear, they must be replaced in duetime. See section ”Coupling”.

If an external supply of sealing, flushing or lubricating liquid isused, make sure supply pressure is 1.0 to 2.0 bar higher thanpressure at the suction nozzle.

The pump rotormust be lockedwhenever the pumpis transported.

-- The pump rotor must be locked to prevent damage to theRESIDUR�-- bearing.

-- To lock the pump rotor, the flushing line attached to thenon--drive end (719.02) including the elbow (731.05) mustbe dismantled.

-- The flushing line must be fastened with a cable tie (81--73acc. to parts list) to a rib on the top casing half (105.02).

-- The free end of the nipple joint (731.04) on the top casinghalf must be closed to prevent contamination.

-- Secure the hex. head bolt (901.17) provided for locking thepump rotor using LOCTITE, type 221, and screw it into thethreaded hole of the cover (160) so that the screw engagesthe centering hole of the pump shaft (211). (see Fig. 6).

-- Lock the rotor axially and radially by tightening the bolt(901.17)according to the tightening torques specified. (SeeFig. 6 ”Locking and Unlocking of the Pump Rotor”, point5.3.1).

Rotor Lock -- Tightening TorquesOn pump with gland packing, the packing must drip slightlyduring operation. The gland cover may therefore only betightened slightly (see Section 8 ”Special Instructions forSubassemblies -- Shaft Seal Variants”).

Tightening-- -- l e s s t h a n / e q u a l t o --g gtorque in Nm

� 10 16 23 30 38 48

Pumpsize 80 - 210 125 - 230 150 - 460 200 - 520 250 - 480 300 - 56080 - 270 125 - 290 150 - 605 200 - 670 250 - 600 300 - 70080 - 370 125 - 365 200 - 320 250 - 370 300 - 435 350 - 430100 - 250 125 - 500 200 - 420 300 - 300 350 - 360 350 - 510100 - 310 150 - 290100 - 375 150 - 360

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7.2.2 Shaft Seal MaintenanceFor requiredmaintenancework on gland packings please referto section 8.1. ”Shaft seal”. Mechanical seals aremaintenance--free.

7.2.3 Bearing MaintenanceThebearings aremaintenance--free. The top deep--grooveballbearing has been supplied at the factory with permanentgrease lubrication. Relubrication is not required. The bottomRESIDUR� bearing is maintenance--free (plain bearing;lubricated by medium pumped).

7.3 DismantlingBeforedismantling, secure thepumpsoas tomakesureit cannot be switched on accidentally. The shut--off

elements in the suction and discharge lines must be closed.

The pump must have cooled down to ambient temperature,pump pressure must be released and the pump must bedrained.Dismantling and reassembly must always be carried out inaccordance with the relevant sectional drawing.

7.3.1 Fundamental Instructions andRecommendations

Repair andmaintenancework to the pumpmust only becarriedout by specially trained personnel, using original spare parts.Observe the safety regulations laid down. Any work on themotor shall be governed by the specifications and regulationsof the respective motor supplier.Dismantling and reassembly must always be carried out inaccordance with the relevant general drawing. The generaldrawing and other relevant documents are found in the annex.The dismantling sequence can be derived from the generaldrawing.In case of damage you can always contact our nearestcustomer service centre.

7.3.2 Preparations for DismantlingThe pump is designed so that the complete rotor can beremoved in the sequence described below without removingthe suction or discharge pipe or disturbing the alignment of thepump unit:-- Close thesuctionanddischarge--sidegatevalvesanddrain

the pump by opening the drain plug (903.01 bottom) andvent plug (903.01 top).

-- Remove any pipes between additional equipment and thepump.

-- Remove the coupling guard.Decouple pump--side coupling half as described in theappendix.

-- Loosen and push back the seal cover (471), if amechanicalseal is fitted.

-- Suspend top casing half (105.02) from lifting tackle andsecure it. (When using a KSB lifting equipment, theoperating instructions ”Lifting Equipment” must beobserved (see appendix).

-- Undo the flange screws (901.01 / 901.02) and separate theupper casing half (105.02) from the lower casing half(105.01) with the aid of the forcing screws. Remove withlifting gear. The interior of the pump (impeller with casingwear rings, shaft seal) is now accessible for inspection.

-- Secure the rotor prior to removing it. WhenusingKSB liftingequipment the Operating Instructions ”Lifting device”must be followed for the removal of the rotor.

-- Remove the screw connection (901.04) and the nuts(920.05) which secure the bearing cover (360) so that thebearing housing can be lifted out of its recess.

-- Lift the rotor and store safely in a horizontal position fordismantling purposes.

-- Remove the nuts (920.02) and lift off the bearing cover(160). The grooved nut (920.01), the spring (950) and thedisc (550.03) can then be removed.

-- Lift off the bearing housing (350.02), the shaft sleeve(524.02) the bearing bush (545) and the spacer sleeve(525).

-- The impeller (234) is located with sliding fit on the shaft andcan normally be removed easily. In case of difficulty, it canbe loosened by gently tapping with a plastic hammer.

-- Remove the shaft seal housing (441) with shaft seal andshaft sleeve (524.01).

-- Remove coupling half.-- Remove the nuts (920.5), bearing housing (350.01 with

spacer ring (550.02) and circlip (932) together with spacerring (550.01)

-- Remove bearing cover (360) and deep groove ball bearing(321).

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7.4 ReassemblyReassembly is effected in reverse order to dismantling. For allwork on the pump unit refer to the general drawing, inconjunction with the list of components, for orientation.The rules of sound engineering practice and also theinstructions for removal and installation of shaft seal, bearings,impeller wear rings and casing wear rings (sections 7.5.1 and7.5.2) must be observed.The tightening torques indicated for nuts and bolts shall beobserved. The table below indicates the tightening torques forthreads depending on the materials used.

Property class (Material) 8.8 10.9 A.-50 A.-70 1.44620,2% yield stress 640 900 210 450

Rp 02 in N/mm2 1) 250 450Metric ISO threads Tightening torque

coarse--pitch fine--pitch MA in Nm

M4 3,1 4,4 1,0 2,15M5 6,1 8,7 2,00 4,25M6 10,4 14,9 3,40 7,30M8 25,2 36,1 8,30 17,7

M8x1 27,2 39,0 8,90 19,1M10 49,5 71,0 16,2 34,8

M10x1,25 52,5 75,4 17,3 36,9M12 85,2 122,2 28,0 59,9

M12x1,5 89,5 128,5 29,4 62,9M12x1,25 93,9 134,7 30,8 66,0

M16 211 302,7 69,2 148M16x1,5 226 324,7 74,3 159

M20 412 591,9 135 290M20x1,5 461 661,0 151 324

M24 710 1019,6 233 276 500M24x2 780 1118,6 256 305 548

M27 1050 1501,3 343 409 736M27x2 1130 1627,1 372 443 797

M30 1420 2036,4 466 554 1000M30x2 1580 2269,9 519 618 1110

M33 1940 2779,4 636 ---- 1360M33x2 2130 3062,6 700 ---- 1500

M36 2480 3552,3 812 ---- 1740M36x3 2630 3775,4 863 ---- 1850

1) Nominal values to DIN ISO 898 Part 1, DIN 267 Part 11 and DIN 267 Part 18

It is imperative to lock and seal the screwed connectionsspecially marked in the general drawings.Symbols for screwed connections to be locked and sealed:

ALTEMP Q NB 50 grease

ALTEMP Q NB 50 grease

Glued in with Loctite 2701

Special adhesive 2503/L 28Desmodur

Caution

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O--rings and V--rings must be replaced and their seats on theshaft must be cleaned. In addition, all the sealing elementsmust be fitted into the respective components beforeinstallation.For assembling the rotor, position the pump shaft (211)securely. All fits, threads and sliding fits of the shaft must becleaned and coated with assembly paste.Insert the keys required for assembly into the pump shaft (211).Mount the impeller (234),whichhasasliding fit.When fitting theimpeller, observe the direction of rotation (see diagrambelow).

For assembling the casing wear rings (502), observe section7.5.2 ”Replacing the casing wear rings”.Put the casing wear rings onto the running surfaces of theimpeller. Ensure that the bezels of the rings are on the outside(towards the bearing). Insert the pins required for fixing thecasing wear rings.The remaining components are fitted first on the movablebearing side (i.e. the drive side) of the pump shaft.Push the shaft protecting sleeve (524.01) onto the pump shaft(211). Ensure that the groove provided engages in the key ofthe impeller.Push the shaft seal housing (441) onto the shaft and install theshaft seal as described in section8.1, ”Glandpacking”. Slip onV--ring (411.01).Insert the radial shaft seal ring (421.02) into the bearing cover(360) and push the bearing cover over the shaft.Heat the deep--grooved ball bearing (321) and fit it onto thepump shaft (211). It is essential to avoid one--sided pressure orhammer blows on the outer races. The bearing is secured bythe disc (550.01) and the circlip (932).To fit the shaft protecting sleeve (524.01), shaft seal housing(441),V--ring (411.01)andbearing cover (360)at thenon--driveend, proceed as described above for the drive side.Heat the deep--groove ball bearing (321) and fit it onto thesleeve (520).Push thesleeve (520)withdeep--grooveball bearing (321)ontothe pump shaft (211) with key (940.01) inserted.Tension the rotor parts elastically with keywayed nut (920) andcup spring (950). For this purpose tension the cup spring (950)to blocking point and then undo the keywayed nut (920) againby half a turn (180°).

This measure is essential to compensate fordifferences in thermal expansion between the

pump shaft (211) and the components fitted on it.

Rotor assembly is now complete.Insert the rotor into the pump casing.Apply Loctite 574 to the casing wear ring surfaces and thesealing surfaces of the casing.Install the rotor, making sure that the direction of rotation iscorrect.Align the rotor and ensure that the fixing pins are correctlyseated in the casing.The pins (561.01) must be positioned as shown in the diagrambelow.Thebearing housings (350.01)must be fastened to the bearingbrackets by means of the screwed connections (901.04), withthesealingcap (580) insertedat thenon--driveend.Theseatingpositions are determined by the recesses.Fit the bearing covers.To assemble the casing cover, apply Loctite 574 to the casingjoint surface of the lower casing half.Tighten the flange bolts diagonally from the inside towards theoutside.Insert the key for fitting the coupling into the pump shaft (211).When fitting the coupling and accessories, refer to the relevantsection of the operating instructions.

(502)

561.01

Casing wear rings

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7.5 Instructions for Replacing Subassemblies

7.5.1 Replacing the Shaft SealProceed as described in section 8.1 and 8.2.

7.5.2 Replacing Casing Wear Rings and / or ImpellerWear Rings

The impeller clearance 1) clearance between impeller 234 andcasing wear ring 502 is given in the table below.For impeller removal proceed as described in section 7.3,”Dismantling”.

After dismantling as described in section 7.3.2, the casingwearrings (502) can be removed.When fitting the rings, ensure thattheir bezels are on the outside (towards the bearing). The pins(561.01) must be positioned as shown in the diagram below.If the impeller has not been fitted with a wear ring at the factory,and changing the casing wear ring alone does not achieveanything close to the required impeller clearance (the impellerneck is badly worn by clearance flows), the impeller neck mustbe turned off on a lathe (contact KSB before doing so) and animpeller wear ring fitted in addition (available as spare part).Alternatively, a new impeller can be supplied at short notice.

Impeller clearances and trim dimensions for impeller wear rings

Clearance (as--new) Dimensions of impeller wear ringNo. Pump

sizeShaftunit

Nominal clea-rance

(max. perm.)

D2 - D1

Min.clearance

S min

Max.clearance

S max

D W 2 D 5 b[mm] [mm] [mm] [mm] [mm]

1 80-210 0,3 0,15 0,2 134 r6 182 80-270 0,3 0,15 0,2 134 r6 183 80-370

400,3 0,15 0,2 134 r6 18

4 100-25040

0,35 0,17 0,2 163 r6 225 100-310 0,35 0,17 0,2 163 r6 226 100-375 0,35 0,17 0,2 163 r6 227 125-230 0,35 0,18 0,23 178 r6 228 125-290 0,35 0,18 0,23 178 r6 229 125-365

500,35 0,18 0,23 178 r6 22

10 125-50050

0,35 0,18 0,23 178 r6 2211 150-290 0,45 0,22 0,26 210 r6 3012 150-360 0,45 0,22 0,26 210 r6 3013 150-460 0,45 0,22 0,26 210 r6 3014 150-605

600,45 0,22 0,26 210 r6 30

15 200-32060

0,5 0,24 0,28 243 r6 3016 200-420 0,5 0,24 0,28 243 r6 3017 200-520 0,5 0,24 0,28 243 r6 3018 200-670 70 0,5 0,24 0,28 243 r6 3019 250-370

700,5 0,24 0,28 276 r6 30

20 250-48080

0,5 0,24 0,28 276 r6 3021 250-600

800,5 0,24 0,28 276 r6 30

22 300-300 70 0,5 0,24 0,28 259 r6 3023 300-435 80 0,6 0,29 0,35 313 r6 3524 300-560

900,6 0,29 0,35 313 r6 35

25 300-70090

0,6 0,29 0,35 313 r6 3526 350-360 80 0,5 0,24 0,28 294 r6 3527 350-430

900,6 0,32 0,37 333 r6 35

28 350-51090

0,6 0,32 0,37 353 r6 35

S (min –max)

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7.6 Monitoring scheduleFor a detailed description of the pump version, componentsand accessories supplied by KSB please refer to section 13 ofthis operating manual.

Component monitored Action Value required

Mechanical seal(if applicable) Check for leakage (daily) see section 8.2 and *

Gland packing(if applicable) Check for leakage (daily) 10 to 120 drops / min.

Suction side measuring instrument, ps(if applicable) Check pressure (daily) *

Discharge side measuring instrument, pd(if applicable) Check pressure (daily) *

Thermometer(suction / discharge nozzle)(if applicable)

Check temperature (weekly) *

Flushing line sight glass(if applicable)

Check flushing water flow(weekly) Water flows

Vibration measurement(if applicable) Check weekly *

Bearing temperature(if applicable)(drive--end rolling element bearing)

Check weekly Section 7.2

Coupling Check weekly Annex from p. 49, detailed manufacturerinformation

Drive(if applicable) See manufacturer’s documentation Ensure contact--free installation

Coupling guard Check monthly No contact permitted

Earthing connection Check monthly Connection must be fitted and marked.

* see list of measuring points (if applicable) in section 13,Annex.

In the event of deviations proceed as described in the tablegiven in section 11.2 (Trouble--shooting).

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8 Special Instructions forSubassemblies (Shaft Seal Variants)

The shaft seal variant supplied is shown in the purchase orderand order--processing documents.

8.1 Gland packingThe gland packings used by KSB are asbestos--free andsuitable for drinking water applications.

Installation and commissioningBefore installation, ensure that the gland space is clean (nopacking remnants or corrosion). The shaft protecting sleevemust be bright and have no scoring. Otherwise a new shaftprotecting sleeve must be used.

Cutting the packing rings to sizeIf moulded packing rings are not available, the rings can bestbe cut to size using a special cutting gauge. If no cutting gaugeis available, take a tube with the same diameter as the shaft,wind the packing around the tube in a spiral and cut the ringsfrom the spiral. We recommend a straight cut.

Installing the packing ringsPush the packing ringswith the stuffingbox insert into theglandspaceoneby one. The joints of the packing ringsmust be offsetby 90°. The number of rings and the arrangement of the lanternring are shown in the general drawing (see appendix). Afterfitting all the packing rings, put on the stuffing box insert andgland cover and tighten them so that the packing rings adapt tothe gland space. Then loosen the gland cover again to relievethe load on the packing. This procedure is not necessary ifmoulded packing rings are used.

CommissioningWhen the pump is started up, the gland must only be gentlytightened (by hand). A high leakage rate (approx. 50 to 200dropsperminute), dependingon the liquidbeing pumped,mustbe accepted until the packing material has settled and hasadapted to the temperature conditions (approx. 10 to 15minutes).Then the gland covermust be carefully and evenly tightened toreduce the leakage to a minimum. If there is no leakage, thereis a risk that the packing will run hot.

Also note the following:Leakage and temperature rise: If necessary, shut down thepump. After a short cooling period (approx. 10 to 15 minutes)the pump can be restarted. The necessary minimum leakagedepends on the liquid being pumped, the pressure, slidingvelocity and temperature. It is approx. 10 to 120 drops perminute (20 drops of water correspond to approx. 1 ml).

DismantlingA packing puller must be used for pulling out the packing rings.

MaintenanceGland packings must be repacked in accordance with thesection ”Installation and commissioning” after prolongedstandstill, repairworkor heavy leakage.Therefore, the leakagerate must be observed during operation, also to avoid possibleoverheating.

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8.2 Mechanical Seal Variants (Mech. Seal Size / Pump Size Combinations)

Mechanical seal variants

No Pump size Shaft unit Nom. mech.seal size

Non--balanced Balanced

dw D for operatingpressures up to 16

bar

for operating pressures> 16 bar

1 80 - 210

2 80 - 270

3 80 - 37040 50 M 7 N 4 / 50 HJ 92 N / 50

4 100 - 25040 50 M 7 N 4 / 50 HJ 92 N / 50

5 100 - 310

6 100 - 375

7 125 - 230

8 125 - 290

9 125 - 36550 60 M 7 N 4/ 60 HJ 92 N / 60

10 125 - 50050 60 M 7 N 4/ 60 HJ 92 N / 60

11 150 - 290

12 150 - 360

13 150 - 460

14 150 - 60560 70 M 7 N 4/ 70 HJ 92 N / 70

15 200 - 32060 70 M 7 N 4/ 70 HJ 92 N / 70

16 200 - 420

17 200 - 520

18 200 - 670 70 80 M 7 N 4/ 80 HJ 92 N / 80

19 250 - 370

70 80 M 7 N 4/ 80 HJ 92 N / 80

20 250 - 48080 90 M 7 N 4/ 90 HJ 92 N / 90

21 250 - 60080 90 M 7 N 4/ 90 HJ 92 N / 90

22 300 - 300 70 80 M 7 N 4/ 80 HJ 92 N / 80

23 300 - 435 80 90 M 7 N 4/ 90 HJ 92 N / 90

24 300 - 56090 11 M 74 N / 110 H 75 N / 110

25 300 - 70090 11 M 74 N / 110 H 75 N / 110

26 350 - 360 80 90 M 7 N 4/ 90 HJ 92 N / 90

27 350 - 43090 110 M 74 N / 110 H 75 N / 110

28 350 - 51090 110 M 74 N / 110 H 75 N / 110

Caution

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8.2.1 Mechanical Seal ”Type H7N4”(Shaft unit dw 40 to 80 mm)

The mechanical seal type H7N4 used is a single--acting,bi--rotational, non--balanced seal which does not requirecirculationpipework in coldwater applications, due to thepumpdesign.

Dry--running of the seal must be avoided atall costs!

InstallationFor the installation of the total seal assembly (mechanical seal,seal housing) see operating instructions for the pump.Theshaft protection sleevesandalso thesurfacesof thecasingare subjected toaccurate finishingprocesseswith regard to theO--ring seats, in order to achieve a complete and reliable seal.Care must be taken during installation to keep these partsabsolutely clean, to avoid the surfaces from being damagedand prevent entry of foreign particles.The seat ring (8) together with the relevant O--ring (9), is fittedinto the seal cover (see general drawing). The O--ring can belubricated foreasy slidingmovement.Special attentionmustbegiven to ensure that pressure is applied evenly. The contactsurfaces are generally fitted dry.Inmechanical seals of theM7N4 design, the rotating assemblyis supplied as one unit, consisting of a housing and pin ( 1 + 5),fitted spring loaded ring (6), O--ring (2), spring (3), thrust plate(4) and grub screws (7). The grub screws (7)must be loosenedso far as to prevent them from protruding from the housing (1)at the inner diameter. The O--ring (2) can be slightly lubricatedto facilitate assembly.The complete rotating assembly is pushed onto the shaftprotection sleeve in compliance with the installationdimensions which are given in the mech. seal drawing, or untilit reaches the stop on the shaft protection sleeve. Finally thegrub screws are tightened and secured with LOCTITE.

Item Description Material No. ofitems

1 Housing Cr-Ni-Mo-steel 12 O-Ring Viton 13 Spring Cr-Ni-Mo-steel 14 Thrust plate Cr-Ni-Mo-steel 15 Pin Cr-Ni-Mo-steel 26 Spring--loaded ring Si-SiC 17 Grub screw Cr-Ni-Mo-steel 28 Seat ring Si-SiC 19 O-Ring Viton 1

Special instructions for mechanical seal assembly-- The contact facesmust only be cleanedwith propyl alcohol

and paper tissue.-- Never use cleaning rags or cloth.-- Clean carefully to remove any smears.

-- Do not touch the contact faces with bare fingers.-- Never use force during mechanical seal assembly.-- Never put the spring--loaded ring and the seat ring face

down on the contact faces without the protective wrapping.-- Cover the contact face with a cardboard washer and press

the seat ring into its position slowly and evenly, lubricatingit with a generous amount of water or alcohol. Use a spacersleeve, if necessary. Verify that the seat ring position isnormal to the shaft axis.

-- In the mechanical seal area, the shaft shall be slightlylubricated with water, alcohol or silicone grease. Sealingelements made of EP rubber must never come intocontact with mineral oil base lubricants (swelling,possibly decomposition).

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CommissioningFlood the pump and the seal chamber with the medium to behandled and vent carefully. The seal is operational now.On single--actingmechanical seals, the pressure in the sealchamber of the pump (stuffing box) must always exceedambient pressure, to prevent any air intake at the seal faces,which would result in dry running and thus failure of themechanical seal.In all operating conditions, the product to be sealed off mustbe available in liquid state at themechanical seal, particularlyduring pump start--up and shutdown. This must be ensured byappropriate facilities on the pump (e.g. heating).Should the mechanical seal fail, the liquid to be sealed off mayspurt out. Take suitable precautions to prevent hazards topersons and the environment, e.g. install splash guards, wearsafety goggles, etc. Proper disposal of leakage shall bearranged for and supervised by the operator.

MaintenanceMechanical seals operated in compliance with the manualare maintenance--free in their entire service life.The mechanical seal should be inspected in accordance withthe plant inspection schedule.During planned plant outage periods the spring--loaded ringsand the seat rings should be checked for visible damage ininstalled condition.If the mechanical seal is inspected during plant outage, thecontact faces should be re--worked.

FaultsDetermine and document the nature of the fault.In the event of a fault as evidenced by excessive leakage,observe the tendency of the leakage amount. Changes inoperating conditions must be documented. If an excessivetemperature rise is detected, themechanical sealmust be shutdown for safety reasons.

During the warranty period the mechanical seal shall only beremoved and dismantled with the manufacturer’s approval orunder instructions of the mechanical seal manufacturer’sservice engineers.

If the fault cannot be remedied by the operator or if the causeis unclear, please contact the KSB service center.

DismantlingFor dismantling of the mechanical seal assembly please referto section 7.3 ”Dismantling”. Grub screws (7) and joint rings(2+9) shall be replaced whenever the mechanical seal hasbeen dismantled!

RepairIf the seal needs to be repaired, always return the completeseal to the manufacturer. The manufacturer will know bestwhich parts can be re--worked and which parts have to bereplaced to ensure an optimum sealing effect.If repair on the spot is necessary, it should be carried out ina clean workshop preferrably by fitters or skilled operatorstaff. Spring--loaded rings, seat rings, all elastomermaterials and springs should be replaced in any case.Make sure to comply with the instructions for handlinghazardous substances and the applicable accidentprevention regulations when repairing, dismantling andcleaningusedmechanical seals. If youhaveanyqueries in thiscontext please inform yourself before commencing anyrepair work.

Spare partsOnly original spare parts shall be used. Non--compliancewith this requirement entails the risk of seal malfunctionswhich may jeopardize the safety of personnel and theenvironment.It will also lead to forfeiture of all warranty claims.

Caution

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8.2.2 Mechanical Seal -- ”Type M74N”(Shaft unit dw = 90 mm)

Thismechanicalseal type isasingle--acting,bi--rotational,non--balanced mechanical seal with multiple springarrangement.

It is imperative to avoid dry running of themechanical seal!

Special instructions for mechanical seal installation

-- Application limits

Pressure to be sealed off p max.: 25 bar

Product temperature t: --40...220 �C

Sliding velocity vg: 20 m/s

-- Safety

Any work on the mechanical seal shall only be performedafter the pump has stopped and pump pressure has beenreleased.In addition to the safety instructions contained in this manual,the general health and accident prevention regulationsshall be observed.

Preparations for installationCheck pump components for:-- chamfered edges (sliding cones 2 mm/ 30° or to DIN

24960).-- radiused transitions-- locating surfaces, surfaces for O--rings: fine finished Rz

10 (DIN 4768)-- Shaft surface in the area of the dynamically loaded joint

ring: roughness depth Rmax 5 �m.

The shaft must be provided with the requisite recesses for thehousing screws of the mechanical seal.Check pump for:-- damage at the mating surfaces with the mechanical seal-- connecting dimensions, rectangularity and concentricity to

the shaft axis

InstallationFor the installation of the total seal assembly (mechanical seal,seal housing) see operating instructions for the pump.Theshaftprotection sleevesandalso thesurfacesof thecasingare subjected toaccurate finishingprocesseswith regard to theO--ring seats, in order to achieve a complete and reliable seal.Care must be taken during installation to keep these partsabsolutely clean, to avoid the surfaces from being damagedand prevent entry of foreign particles.

The seat ring (8) together with the relevant O--ring (9), is fittedinto the seal cover (see general drawing). The O--ring can belubricated for easy sliding movement. Special attention mustbe given to ensure that pressure is applied evenly. The contactsurfaces are generally fitted dry.Inmechanical seals of theM74N design, the rotating assemblyis supplied as one unit, consisting of a housing and pin ( 1 + 5),fitted spring loaded ring (6), O--ring (2), spring (3), thrust plate(4) and grub screws (7). The grub screws (7)must be loosenedso far as to prevent them from protruding from the housing (1)at the inner diameter. The O--ring (2) can be slightly lubricatedto facilitate assembly.The complete rotating assembly is pushed onto the shaftprotection sleeve in compliance with the installationdimensions which are given in the mech. seal drawing, or untilit reaches the stop on the shaft protection sleeve. Finally thegrub screws are tightened and secured with LOCTITE.

Degrease the grubscrews and insertwitha threadsealant(e.g. Loctite). Usenew grub screwswhenever the me-chanical seal hasbeen dismantled!

Item Description Material No. ofitems

1 Housing Cr-Ni-Mo-steel 12 O--ring Compat. elastomers 13 Spring Cr-Ni-Mo-steel 14 Thrust plate Cr-Ni-Mo-steel 15 Pin Cr-Ni-Mo-steel 26 Rotating ring Buka, Buke, Bume 17 Grub screw Cr-Ni-Mo-steel 28 Seat ring Buke, Buko, Buka 19 O--ring Compat. elastomers 1

-- Apply a thin coat of grease to the shaft in the mechanicalseal area.

-- Sealing elements made of EP rubber must never comeinto contact with mineral oil base lubricants (swelling,possibly decomposition).

-- Unwrap the mechanical seal and inspect for damage to thespring--loaded ring and the seat ring, the O--rings and themating surfaces.

-- Never put the spring--loaded ring and the seat ring facedown on the contact faces without the protective wrapping.

-- Thoroughlycleanall componentswithalcohol andcellulosetissue.

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22

InstallationNever use force during mechanical seal installation.-- Slip the degreased O--ring onto the seat ring.-- Cover the contact face with a cardboard washer.-- Push the seat ring slowly and evenly into its seat. Use a

spacer sleeve, if necessary. Lubricate with a generousamount of water or alcohol.

-- Verify that the seat ring position is normal to the shaft axis.-- Push the rotating assembly with the degreased joint rings

onto the shaft. Thread in the degreased grub screws with1 drop of thread sealant each (e.g. Loctite No. 243) andposition themechanical seal by tightening the grub screws.The installation dimensions given in the drawing must beadhered to.

-- The contact facesmust only be cleanedwith propyl alcoholand paper tissue (no cleaning rags or cloth). Cleancarefullyto remove any smears. Do not touch the contact faces withbare fingers afterwards.

The contact faces must not be lubricated; they must be cleanand dry.-- Assemble the seal cover with the installed seat ring.

CommissioningFlood the pump and the seal chamber with the medium to behandled and vent carefully. The seal is operational now.

Reliable seal operationOn single--actingmechanical seals, the pressure in the sealchamber of the pump (stuffing box) must always exceedambient pressure, to prevent any air intake at the seal faces,which would result in dry running and thus failure of themechanical seal.In all operating conditions, the product to be sealed off mustbe available in liquid state at themechanical seal, particularlyduring pump start--up and shutdown. This must be ensured byappropriate facilities on the pump (e.g. heating).If the operating conditions indicated are observed and theinstructions given in this operating manual are complied with,the mechanical seal can be expected to give trouble--freeoperation.

Should the mechanical seal fail, the liquid to be sealedoff may spurt out. Take suitable precautions to

prevent hazards to persons and the environment, e.g. installsplash guards, wear safety goggles, etc. Proper disposal ofleakage shall be arranged for and supervised by the operator.

FaultsDetermine and document the nature of the fault.In the event of a fault as evidenced by excessive leakage,observe the tendency of the leakage amount. Changes inoperating conditions must be documented. If an excessivetemperature rise is detected, themechanical sealmust be shutdown for safety reasons.A continuous flow of leakage indicates a fault.During the warranty period the mechanical seal shall only beremoved and dismantled with the manufacturer’s approval orunder instructions of the mechanical seal manufacturer’sservice engineers.If the fault cannot be remedied by the operator or if the causeis unclear, please contact the KSB service centre.

MaintenanceMechanical seals operated in compliance with the manual aremaintenance--free; however, wear parts will have to bereplaced as required.The mechanical seal should be inspected in accordance withthe plant inspection schedule. We recommend to have themechanical seal inspected by KSB service centre.If the mechanical seal is inspected during plant outage, thecontact faces should be re--worked and all elastomer seals andsprings should be replaced.

ReparaturIf the seal needs to be repaired, always return the completeseal to the manufacturer. The manufacturer will know bestwhich parts can be re--worked and which parts have to bereplaced to ensure an optimum sealing effect.If repair on the spot is absolutely necessary (e.g. no sparesealavailable, long transportdistances,problemswithcustomsprocedures), skilled operator staff may carry out the repairwork in a clean workshop to the directions of KSB servicecentres.

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Mechanical seal removalShut down the pump in accordancewith the operating manual, allow to cool down andrelease pump pressure.

There must be no pumped product at themechanical seal � The pump must be drained.

Secure the pump to prevent inadvertent start--up.

Follow the safety instructions(safety data sheets)!

Make sure to comply with the applicable accidentprevention regulations when removing a mechanical seal.Also observe the instructions for handling hazardoussubstances if the mechanical seal has already been inoperation. If you have any queries about the applicableregulations please inform yourself before commencing anyrepair work.Any work on the mechanical seal is only permitted with thepump shut down and pump pressure released.Removal of the mechanical seal shall be performedanalogously with mechanical seal installation, but in reverseorder.

Removing the subassemblySee section 7.3.-- Replace the grub screw (7) and the joint rings (2+9)

whenever the mechanical seal has been dismantled.

Spare parts

Only genuine spare parts shall be used. Non--compliancewith this requirement entails the risk of seal malfunctionswhich may jeopardize the safety of personnel and theenvironment.

It will also lead to forfeiture of all warranty claims.To keep acomplete spare seal on stock.

8.2.3 Mechanical Seal ”Type HJ92N ”(Shaft unit dw = 40 to 80 mm)

Note:

Refer to sections 8.2.1 and 8.2.2 for general recommendationsand instructions for handling this seal type.

For detailed information please refer to the operating manualfor seal type HJ92N.

24 Operating maual mechanical sealRev. 0, 13.02.2004

OPERATING MANUALMECHANICAL SEAL (MS)

HJ92N

PLEASE READ this manual carefully and OBSERVE the information contained as to:H Safety H Storage H Installation H Start up H Maintenance H Repair

J SAFETY

Any person in the operator’s plantwho is involved in the installa-tion, removal, operation, commissioning and maintenance ofthe mechanical seal must have read and thoroughly under-stood these operating instructions, particularly the safety in-structions contained therein. It is advisable for the operator tohave this confirmed.

Themechanical seal is a precision product (ISO9001) and safeto operate. However, it may constitute a hazard if it is not usedin accordance with its designated use, or if operated improperlyby unskilled personnel.

The operator has to determine the consequences of any me-chanical seal failure and decide whether safety precautionsneed to be taken to protect personnel or the environment.

The pump shall be installed in such away that any fluid spurtingout cannot cause personal injury and that leakage can be pro-perly disposed of.

Any operating mode liable to impair the safe and reliable func-tion of the mechanical seal is not permitted.Mechanical seals shall only be installed, operated, removed orrepaired by authorized, qualified and appropriately instructedpersonnel.

Any work on the mechanical seal shall only be performed withthe pump shut down and the pump pressure released.Staff responsibilities for the work involved must be clearly defi-ned and complied with, to prevent unclear competencies withregard to safety aspects.

In addition to the instructions contained in this manual, the ge-neral occupational health and safety regulations must be adhe-red to.

Unauthorized modifications and alterations liable to jeopardizethe safe operation of the mechanical seal are not permitted.

J DECLARATION

within the meaning of EC Directive ”Machinery” 98/37/EC.

A mechanical seal does not function independently. It is inten-ded to be incorporated into or assembled with machinery.

J OPERATING LIMITSShaft diameter dw: 18 to 100 mmPress. to be sealed off p max.: 25 bar *)

Fluid temperature t: --40 to 220 �CSliding velocity vg: 20 m/s*) depending on the seal face materialsThe mechanical seal shall not be operated at several applica-tion limits at the same time.Higher loads (pressure, temperature, speed) may lead to in-creased wear and damage the contact faces or the elastomerelements.Such operating conditions would shorten the useful life of theseal but also entail the risk of sudden seal failure with hazardsto personnel and the environment.

J OPERATING DATAThe operating data for the application in question, such as fluidto be sealed off, operating pressure, operating temperature, ro-tational speed, etc., are indicated on the respective pump datasheets.

J DESIGNATED USEAny operation outside the operating conditions stated in the”Operating Limits” section is deemed to be non--conformingwith the designated use.To ensure safe operation of themechanical seal, check with theseal manufacturer before using the seal for other operatingconditions or in a different location of operation.

J MATERIALSMaterials as per drawing and/or order.

J DRAWINGSGeneral assembly drawing of pump.The applicable design is shown on the general pump drawingin the original scale and latest revision, see section 9 of thepump’s operating manual, which shall be used in conjunctionwith this document.

J SPECIFICATIONH Single mechanical sealH BalancedH Bi--rotationalH Connecting dimensions to DIN 24960 KBH Installation dimensions l1K

25Operating maual mechanical sealRev. 0, 13.02.2004

Due to their protected spring (1.5),mechanical seals of this typeare particularly suitable for fluids containing solids and/or highlyviscous fluids, for ex. in sugar, paper or waste water applica-tions. The seal design is rugged and reliable. The spring neitherclogs nor sticks. Max. axial end play between shaft and hou-sing: 0.5 mm in any direction.For operation at negative pressures (down to --0.2 bar), no seatlock is required for the seat ring (2).Torque transmission between the shaft and the seal is normallyeffected by grub screws(1.6); or by special drive elements (1.2)on individual models.

J LIQUID SUPPLY TO MECHANICALSEAL

To ensure trouble--free operation of the mechanical seal, a sui-table circulation process has been selected on the pump, seesection 9 of the pump’s operating manual. This process avoidsproduct deposits in the seal chamber.

J EMISSIONSMechanical seals are dynamic seals which for physical andtechnical reasons cannot be completely leak--free. The amountof leakage largely depends on the seal selection, production to-lerances, operating conditions, smooth running of themachine,etc. Compared with other dynamic sealing systems, however,mechanical seals have little leakage.Should the mechanical seal fail, the hot liquid or steam to besealed off may spurt out. Splash guards fitted on the machine,safety goggles worn by the operating staff, etc.may prevent ha-zards to persons. The operator/owner is responsible for thepro-per disposal of leakage, in order to prevent hazards to the envi-ronment.

Leakage may be liquid or gaseous, its aggressiveness corres-ponding to that of the fluid to be sealed off.Anymechanical seal leakagemust be drained off in a controlledway and safely disposed of.

.Components which may come into contact with the seal lea-kage shall either be corrosion resistant or must be adequatelyprotected.

J STORAGEUnless otherwise agreed in the contract, mechanical seals aredelivered in standard packaging suitable for dry transport bytruck, train or plane. The symbols or handling instructions givenon the packaging must be adhered to.For incoming goods inspection:D Check packaging for external damage.D Carefully open packaging, making sure not to damage or

lose any components packed separately.D Check consignment for completeness (delivery note). The

supplier shall be notified immediately of any damagedgoods or missing parts.

The instructions given below shall apply both to mechanicalseals delivered and stored in their undamaged, original packa-ging, and to mechanical seals already installed in a pump,which have not been in operation yet.

The mechanical seals need not be preserved.

D Do not apply anti--corrosives.' Risk of deposits and possible chemical attacks on ela-

stomer secondary seals.

When applying preservatives to entire systems where mecha-nical seals are installed please check the following:

D Verify the compatibility of the preservatives chosen with thematerials of construction and the elastomer components ofthe mechanical seal.

D Verify thatmechanical sealmovement is not restricted by re-sin deposits or sticking.

During storage, seal face materials and elastomers will un-dergo material specific time dependent changes (distortion,ageing),which can impair the perfect function of themechanicalseal. The specified storage period must therefore be compliedwith.The manufacturer cannot be held responsible for damage re-sulting from improper storage.The room where mechanical seals are kept must be dust--freeand moderately ventilated, with an even temperature. We re-commend: relative humidity below 65%, temperature between15 �C and 25 �C.

The mechanical seal shall be protected from:

D direct heat from sun, heatingD ozone and ultraviolet light from halogen lamps, fluorescent

lamps, sunlight, arc welding' danger of embrittlement of elastomer materials

The seals shall be stored in their original packaging on a levelsurface.

The mechanical seal needs to be checked:D after a storage period of approx. 2--3 yearsD if the packaging has been damagedD after a shock load (e.g. if the mechanical seal package has

been dropped)' at the manufacturer’s workshop or nearest service centre.

J BEFORE INSTALLATIONChecks to be carried out on the pump components:

Shaft surface in the area of the dynamically loaded seal ring:roughness depth Rmax 5 �m.

Checks to be carried out on the pump:

D Check contact surfaces between the pump and themecha-nical seal for damage.

D Connecting dimensions, squareness and concentricity toshaft.

D Shaft run--out as per DIN ISO 5199: between 50 �m and100 �m, depending on the diameter.

D Apply a thin coat of suitable grease to the shaft in themech.seal area.

' Never use mineral oil base lubricants on sealing elementsmade of ethylene propylene rubber (swelling, possibly de-composition).

' Grease recommended for elastomer sealing elements(O--rings, etc.): type ”TURMOPOLGREASE SH2”, produ-cer: Lubricant Consult (LUBCON).

26 Operating maual mechanical sealRev. 0, 13.02.2004

' Double PTFE encapsulated O--rings must be fitted so thatthe joint of the outer sheath points in opposite direction tothe mounting direction, so that the friction force generatedwhen sliding on the O--ring closes the joint. Kinks in the foilwill result in leakage.

J INSTALLATION TOOLS / EQUIPMENTD Propyl alcohol + paper tissue (no cleaning rags)D Lubricating grease for elastomer seals: type ”TURMOPOLGREASE

SH2”, producer: Lubricant Consult (LUBCON)D Thread--locking compound, e.g. type ”LoctiteR Nr. 243”,

producer: Loctite CorporationD O--ring extractorD Set of hex. keys (WAF 2 mm -- 6 mm)D Cardboard washers to protect the contact faces during in-

stallationD Manual screw press (compulsory from DN 80 mm).

J INSTALLATIONRefer to the general pump assembly drawing when installingthe mechanical seal.Mechanical seals are precision--machined machinery compo-nents which have been inspected several times. They must beinstalled with due care and in compliance with certain procedu-res, particularly regarding the contact faces and elastomerseals.Utmost cleanliness must be ensured in the immediate vicinityof the location where a mechanical seal is to be installed.Never use force when installing a mechanical seal.D Unpack the seal and inspect the spring--loaded ring, seat

ring, O--rings and contact faces for damage.' Never place the spring--loaded ring and the seat ring on

the table facing down without protecting the contact fa-ces.

D Thoroughly clean all parts with alcohol and paper tissue.The sequence of operations required to install the mechanicalseal in the machine depends on the design of the machine inquestion, which is described in the pump’s operating manual.

Unless otherwise stated, apply a very thin coat of grease toO--rings which will slide into or onto other components duringmechanical seal installation.

Possible installation sequence:D Slide the degreased O--ring onto the seat ring.D Cover the contact face of the seat ring with a cardboard

washer. Generously lubricate the seat ring with water or al-cohol and press it slowly and evenly into its seat.Use a spa-cer, if necessary. Check squareness of seat ring to the shaftaxis.

D Apply a thin coat of grease to the shaft protecting sleeve inthe mechanical seal area.' Never use mineral oil base lubricants on sealing ele-

ments made of ethylene propylene rubber (swelling,possibly decomposition).

D Slide the rotating seal assembly with greased O--rings ontothe shaft protecting sleeve.

D Fit the degreased grub screws, having applied one drop ofthread--locking compound (e.g. Loctite R No. 243) to eachscrew.

D Tighten the grub screws to lock the torque--transmittingsleeve into place.

D Clean the contact faceswith propyl alcoholand paper tissue(no cloth, no cleaning rags!) to remove any smears. Donot touch the contact faces with bare fingers after that.' Donot apply lubricants to the contact faces. The contact

faces must be installed in clean and dry condition.D Fit the seal cover with pre--assembled seat ring.

J COMMISSIONINGPrime the pump and the seal chamber with the fluid handledand vent thoroughly. The seal is now ready for operation.

J SAFE OPERATIONFor single mechanical seals, the pressure in the seal chamberof the pump must always exceed ambient pressure, to preventany air intake at the seal faces,whichwould result in dry runningand thus failure of the mechanical seal.In all operating conditions, the product to be sealed off must beavailable in liquid state at the mechanical seal, particularly du-ring pump start--up and shutdown.If the operating conditions indicated are observed and the in-structions given in this operating manual are complied with, themechanical seal can be expected to give trouble--free opera-tion.

J HEALTH AND SAFETYMechanical seals are often used for sealing off hazardous sub-stances (chemicals, pharmaceuticals, etc.). The applicable in-structions and regulations for handling hazardous materialsmust absolutely be adhered to.

27Operating maual mechanical sealRev. 0, 13.02.2004

Should the mechanical seal fail, the hot liquid or steam to besealed off may spurt out. Splash guards fitted on the machine,safety goggles worn by the operating staff, etc.may prevent ha-zards to persons. The operator/owner is responsible for thepro-per disposal of leakage, in order to prevent hazards to the envi-ronment..

J FAULTS/MALFUNCTIONSDetermine and document the nature of the fault/malfunction.In the event of a fault as evidenced by excessive leakage, ob-serve the tendency of the leakage amount. Changes in opera-ting conditions must be documented. If an excessive tempera-ture rise is detected, themechanical sealmust be shut down forsafety reasons.A continuous flowof leakage indicates a fault/malfunction at themechanical seal.During thewarranty period themechanical seal shall only be re-moved and dismantled with the manufacturer’s approval or inthe presence of his representative.If the fault/malfunction cannot be remedied by the operator orif the cause is unclear, please contact your responsible KSBservice centre.

J SERVICING / MAINTENANCEMechanical seals operated in compliance with manual aremaintenance--free. Wear parts, however, must be replaced asrequired.The mechanical seal shall be inspected in accordance with theplant inspection schedule. We recommend to have themecha-nical seal inspected by competent KSB service staff.If the mechanical seal is removed during plant inspection, thecontact faces shall be re--worked and all elastomer seals andsprings shall be replaced.

J REPAIRIf the seal needs to be repaired, always return the complete sealto the manufacturer. The manufacturer’s service personnel willknow best which parts can be re--worked and which parts haveto be replaced to ensure an optimum sealing effect.If repair on the spot is absolutely necessary (e.g. no spare sealavailable, long transport distances, problemswith customs pro-cedures), skilled operator staff may carry out the repair work ina cleanworkshop to the directions of the seal manufacturer’s fit-ters.

J SPARE PARTSUse only genuine spare parts, to preventD the risk of mechanical seal malfunction, involving hazards

to persons and the environment.D forfeiture of any and all warranty claims.To ensure quick mechanical seal replacement, we recommendto stock a complete spare seal.

J REMOVING THE SEAL FROMTHE PUMP

D Shut down the pump, allow to cool down and release pres-sure as per operating instructions

D No product should contact the mechanical seal � Drain thepump, if necessary!

D Secure the pump against inadvertent start--up!D Follow the safety instructions (safety data sheets)!When removing the mechanical seal make sure to observe theapplicable health and safety regulations, as well as the regula-tions for handling hazardous substances, if themechanical sealhas already been in operation. If in doubt, the necessary infor-mation has to be obtained before starting repair work.Any work on the mechanical seal shall only be performed withthe pump shut down and the pump pressure released.The sequence of operations required to remove themechanicalseal from the pumpdepends on the design of the pump in ques-tion, which is described in the pump’s operating manual.Removal of the mechanical seal shall be effected in analogywith, but in reverse order to, installation.

J CUSTOMER SERVICEServices provided by the seal manufacturer range from plan-ning advice to product support after commissioning.For this purpose, themanufacturer hasestablished aworldwidenetwork of subsidiaries abroad, partner companies, sales offi-ces and service centres, to handle any problems.

J PURCHASE ORDERSFor enquiries and purchase orders, the following details are re-quired:D KSB order No.D No. of general pump assembly drawingD Part itemNo., description,material, quantity as per drawing.

J DISPOSALUsually, mechanical seals can easily be disposed of after a tho-rough cleaning.D Metal parts (steel, stainless steel, non--ferrous metals),

shall be sorted and disposed of in theappropriatewasteme-tal collection facility.

D Plastics (elastomers, PTFE) are special waste. After sor-ting, some of them can be recycled.' CAUTION!Material containing fluorine must not be inci-

nerated.D Ceramic contact facematerials (carbon, ceramics, carbide)

can be separated from their carrier materials and -- beingphysiologically harmless -- disposed of as residual waste.

We reserve the right to technicalmodifications designed toimprove the product, even if they arenotmentioned in thisma-nual yet.

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8.2.4 Mechanical Seal -- ”Type H75N”(Shaft unit dw = 90 mm)

General instructions concerning assembly/installation, com-missioning, maintenance, faults and repair have already beengiven in sections 8.2.1 and 8.2.2.(For detailed information please refer to operating manual forseal type H75N).

29Operating maual mechanical sealRev. 0, 13.02.2004

OPERATING MANUAL

BURGMANN MECHANICAL (M.S.)

H75N

PLEASE READ this manual carefully and OBSERVE the information contained as to:H Safety H Storage H Installation H Start up H Maintenance H Repair

J SAFETY

Any person in the operator’s plantwho is involved in the installa-tion, removal, operation, commissioning and maintenance ofthe mechanical seal must have read and thoroughly under-stood these operating instructions, particularly the safety in-structions contained therein. It is advisable for the operator tohave this confirmed.

Themechanical seal is a precision product (ISO9001) and safeto operate. However, they may constitute a hazard if they arenot used in accordancewith their designated use, or if operatedimproperly by unskilled personnel.

The operator has to determine the consequences of any me-chanical seal failure and decide whether safety precautionsneed to be taken to protect personnel or the environment.

The pump shall be installed in such away that any fluid spurtingout cannot cause personal injury and that leakage can be pro-perly disposed of.

Any operating mode liable to impair the safe and reliable func-tion of the mechanical seal is not permitted.

Mechanical seals shall only be installed, operated, removed orrepaired by authorized, qualified and appropriately instructedpersonnel.

Any work on the mechanical seal shall only be performed withthe pump shut down and the pump pressure released.

Staff responsibilities for the work involved must be clearly defi-ned and complied with, to prevent unclear competencies withregard to safety aspects..

In addition to the instructions contained in this manual, the ge-neral occupational health and safety regulations must be adhe-red to.

Unauthorized modifications and alterations liable to jeopardizethe safe operation of the mechanical seal are not permitted.

J DECLARATION

within the meaning of EC Directive ”Machinery” 98/37/EC.

A mechanical seal does not function independently. It is inten-ded to be incorporated into or assembled with machinery.

J OPERATING LIMITSShaft diameter dw: 28 to 100 mmPress. to be sealed off p max.: 40 bar *)Fluid temperature t: --40 to 220 �CSliding velocity vg: 20 m/s*) depending on the seal face materialsThe mechanical seal shall not be operated at several applica-tion limits at the same time.Higher loads (pressure, temperature, speed) may lead to in-creased wear and damage the contact faces or the elastomerelements.Such operating conditions would shorten the useful life of theseal but also entail the risk of sudden seal failure with hazardsto personnel and the environment.

J SPECIFICATIONThe operating data for the application in question, such as fluidto be sealed off, operating pressure, operating temperature, ro-tational speed, etc., are indicated on the respective pump datasheets.

J DESIGNATED USEAny operation outside the operating conditions stated in the”Operating Limits” section is deemed to be non--conformingwith the designated use.To ensure safe operation of themechanical seal, check with theseal manufacturer before using the seal for other operatingconditions or in a different location of operation.

J MATERIALSMaterials as per drawing and/or order.

J DRAWINGSGeneral assembly drawing of pump.The applicable design is shown on the general pump drawingin the original scale and latest revision, see section 9 of thepump’s operating manual, which shall be used in conjunctionwith this document.

J SPECIFICATIONH Single mechanical sealH BalancedH Bi--rotationalH Rotating spring--loaded ringH Stationary seat ring

30 Operating maual mechanical sealRev. 0, 13.02.2004

H Multiple springs in guide sleevesH axial mobility/play up to dw 55 = � 2 mm, and � 3 mmH Torque transmission by grub screwsH Connecting dimensions to DIN 24960 KBH Installation dimensions l1K

J LIQUID SUPPLY TO MECHANICALSEAL

To ensure trouble--free operation of the mechanical seal, a sui-table circulation process has been selected on the pump, seesection 9 of the pump’s operating manual. This process avoidsproduct deposits in the seal chamber.

J EMISSIONS

Mechanical seals are dynamic seals which for physical andtechnical reasons cannot be completely leak--free. The amountof leakage largely depends on the seal selection, production to-lerances, operating conditions, smooth running of themachine,etc. Compared with other dynamic sealing systems, however,mechanical seals have little leakage.

Leakage may be liquid or gaseous, its aggressiveness corres-ponding to that of the fluid to be sealed off.

Anymechanical seal leakagemust be drained off in a controlledway and safely disposed of.

.Components which may come into contact with the seal lea-kage shall either be corrosion resistant or must be adequatelyprotected.

J STORAGE

Unless otherwise agreed in the contract, mechanical seals aredelivered in standard packaging suitable for dry transport bytruck, train or plane. The symbols or handling instructions givenon the packaging must be adhered to.

For incoming goods inspection:

D Check packaging for external damage.D Carefully open packaging, making sure not to damage or

lose any components packed separately.D Check consignment for completeness (delivery note). The

supplier shall be notified immediately of any damagedgoods or missing parts.

The instructions given below shall apply both to mechanicalseals delivered and stored in their undamaged, original packa-ging, and to mechanical seals already installed in a pump,which have not been in operation yet.

The mechanical seals need not be preserved.D Do not apply anti--corrosives.

' Risk of deposits and possibly chemical attack of the ela-stomer secondary sealing elements.

When applying preservatives to entire systems where mecha-nical seals are installed please check the following:D Verify the compatibility of the preservatives chosen with the

materials of construction and the elastomer components ofthe mechanical seal.

D Verify thatmechanical sealmovement is not restricted by re-sin deposits or sticking.

During storage, seal face materials and elastomers will un-dergo material specific time dependent changes (distortion,ageing),which can impair the perfect function of themechanicalseal. The specified storage period must therefore be compliedwith.The manufacturer cannot be held responsible for damage re-sulting from improper storage.The room where mechanical seals are kept must be dust--freeand moderately ventilated, with an even temperature. We re-commend: relative humidity below 65%, temperature between15 �C and 25 �C.

The mechanical seal shall be protected from:D direct heat from sun, heatingD ozone and ultraviolet light from halogen lamps, fluorescent

lamps, sunlight, arc welding' danger of embrittlement of elastomer materials.The seals shall be stored in their original packaging on a levelsurface.

The mechanical seal needs to be checked:D after a storage period of approx. 2--3 yearsD if the packaging has been damagedD after a shock load (e.g. if the mechanical seal package has

been dropped)' at the manufacturer’s workshop or nearest service centre.

J BEFORE INSTALLATIONChecks to be carried out on the pump components:Shaft surface in the area of the dynamically loaded seal ring:roughness depth Rmax 5 �m.Checks to be carried out on the pump:D Check contact surfaces between the pump and themecha-

nical seal for damage.D Connecting dimensions, squareness and concentricity to

shaftD Shaft run--out as per DIN ISO 5199: between 50 �m and

100 �m, depending on the diameter.D Apply a thin coat of a suitable grease to the shaft in the

mech. seal area.' Never use mineral oil base lubricants on sealing elements

made of ethylene propylene rubber (swelling, possibly de-composition).

' Grease recommended for elastomer sealing elements(O--rings, etc.): type ”TURMOPOLGREASE SH2”, produ-cer: Lubricant Consult (LUBCON).

' Double PTFE encapsulated O--rings must be fitted so thatthe joint of the outer sheath points in opposite direction tothe mounting direction, so that the friction force generatedwhen sliding on the O--ring closes the joint. Kinks in the foilwill result in leakage.

J INSTALLATION TOOLS / EQUIPMENTD Propyl alcohol + paper tissue (no cleaning rags)D lubricant for elastomer--sealing rings: Type ”TURMOPOL-

GREASE SH2”, make Lubricant Consult (LUBCON)

31Operating maual mechanical sealRev. 0, 13.02.2004

D Thread--locking compound, e.g. type ”LoctiteR Nr. 243”,producer: Loctite Corporation

D O--ring extractorD Set of hex. keys (WAF 2 mm -- 6 mm)D Cardboard washers to protect the contact faces during in-

stallationD Manual screw press (compulsory from DN 80 mm)

J INSTALLATIONRefer to the general pump assembly drawing when installingthe mechanical seal.

Mechanical seals are precision--machined machinery compo-nents which have been inspected several times. They must beinstalled with due care and in compliance with certain procedu-res, particularly regarding the contact faces and elastomerseals.Utmost cleanliness must be ensured in the immediate vicinityof the location where a mechanical seal is to be installed.Never use force when installing a mechanical seal.Unpack the seal and inspect the spring--loaded ring, seat ring,O--rings and contact faces for damage.D Never place the spring--loaded ring and the seat ring on the

table facing down without protecting the contact faces.D Thoroughly clean all parts with alcohol and paper tissue.

The sequence of operations required to install the mechanicalseal in the machine depends on the design of the machine inquestion, which is described in the pump’s operating manual.

Unless otherwise stated, apply a very thin coat of grease toO--rings which will slide into or onto other components duringmechanical seal installation.

Fig. 1: General mech. seal design

Primary seal components1.1 Spring--loaded ring2 Seat ring

Secondary seal elements1.4 O--ring (dynamic)3 O--ring (static)

Spring components1.5 Guide sleeve1.6 Spring

Torque transmission and housing components1.2 Torque--transmitting sleeve1.3 Thrust ring1.7 Grub screw

Possible installation sequence:D Slide the degreased O--ring onto the seat ring.D Cover the contact face of the seat ring with a cardboard

washer. Generously lubricate the seat ring with water or al-cohol and press it slowly and evenly into its seat.Use a spa-cer, if necessary. Check squareness of seat ring to the shaftaxis.

D Apply a thin coat of grease to the shaft protecting sleeve inthe mechanical seal area.' Never use mineral oil base lubricants on sealing ele-

ments made of ethylene propylene rubber (swelling,possibly decomposition).

D Slide the rotating seal assembly with greased O--rings ontothe shaft protecting sleeve.

D Fit the degreased grub screws, having applied one drop ofthread--locking compound (e.g. Loctite R No. 243) to eachscrew.

D Tighten the grub screws to lock the torque--transmittingsleeve in place.

D Clean the contact faceswith propyl alcoholand paper tissue(no cloth, no cleaning rags!) to remove any smears. Donot touch the contact faces with bare fingers after that.' Donot apply lubricants to the contact faces. The contact

faces must be installed in clean and dry condition.D Fit the seal cover with pre--assembled seat ring.

J COMMISSIONINGPrime the pump and the seal chamber with the fluid handledand vent thoroughly. The seal is now ready for operation.

J SAFE OPERATIONFor single mechanical seals, the pressure in the seal chamberof the pump must always exceed ambient pressure, to preventany air intake at the seal faces,whichwould result in dry runningand thus failure of the mechanical seal.In all operating conditions, the product to be sealed off must beavailable in liquid state at the mechanical seal, particularly du-ring pump start--up and shutdown.If the operating conditions indicated are observed and the in-structions given in this operating manual are complied with, themechanical seal can be expected to give trouble--free opera-tion.

J HEALTH AND SAFETYMechanical seals are often used for sealing off hazardous sub-stances (chemicals, pharmaceuticals, etc.). The applicable in-structions and regulations for handling hazardous materialsmust absolutely be adhered to.

32 Operating maual mechanical sealRev. 0, 13.02.2004

Should the mechanical seal fail, the hot liquid or steam to besealed off may spurt out. Splash guards fitted on the machine,safety goggles worn by the operating staff, etc.may prevent ha-zards to persons. The operator/owner is responsible for thepro-per disposal of leakage, in order to prevent hazards to the envi-ronment.

J FAULTS/MALFUNCTIONSDetermine and document the nature of the fault/malfunction.

In the event of a fault as evidenced by excessive leakage, ob-serve the tendency of the leakage amount. Changes in opera-ting conditions must be documented. If an excessive tempera-ture rise is detected, themechanical sealmust be shut down forsafety reasons.

A continuous flowof leakage indicates a fault/malfunction at themechanical seal.

During thewarranty period themechanical seal shall only be re-moved and dismantled with the manufacturer’s approval or inthe presence of his representative.

If the fault/malfunction cannot be remedied by the operator orif the cause is unclear, please contact your responsible KSBservice centre.

J SERVICING / MAINTENANCEMechanical seals operated in compliance with manual aremaintenance--free. Wear parts, however, must be replaced asrequired.

The mechanical seal shall be inspected in accordance with theplant inspection schedule. We recommend to have themecha-nical seal inspected by competent KSB service staff.

If the mechanical seal is removed during plant inspection, thecontact faces shall be re--worked and all elastomer seals andsprings shall be replaced.

J REPAIRIf the seal needs to be repaired, always return the complete sealto the manufacturer. The manufacturer’s service personnel willknow best which parts can be re--worked and which parts haveto be replaced to ensure an optimum sealing effect.

If repair on the spot is absolutely necessary (e.g. no spare sealavailable, long transport distances, problemswith customs pro-cedures), skilled operator staff may carry out the repair work ina cleanworkshop to the directions of the seal manufacturer’s fit-ters.

J SPARE PARTSUse only genuine spare parts, to prevent

D the risk of mechanical seal malfunction, involving hazardsto persons and the environment.

D forfeiture of any and all warranty claims.

To ensure quick mechanical seal replacement, we recommendto stock a complete spare seal.

J REMOVING THE SEAL FROMTHE PUMP

D Shut down the pump, allow to cool down and release pres-sure as per operating instructions.

D Noproduct should contact the mechanical seal �Drain thepump, if necessary!

D Secure the pump against inadvertent start--up!D Follow the safety instructions (safety data sheets)!When removing the mechanical seal make sure to observe theapplicable health and safety regulations, as well as the regula-tions for handling hazardous substances, if themechanical sealhave already been in operation. If in doubt, the necessary infor-mation has to be obtained before starting repair work.

Any work on the mechanical seal shall only be performed withthe pump shut down and the pump pressure released.The sequence of operations required to remove themechanicalseal from the pumpdepends on the design of the pump in ques-tion, which is described in the pump’s operating manual.Removal of the mechanical seal shall be effected in analogywith, but in reverse order to, installation.

J CUSTOMER SERVICEServices provided by the seal manufacturer range from plan-ning advice to product support after commissioning.For this purpose, themanufacturer hasestablished aworldwidenetwork of subsidiaries abroad, partner companies, sales offi-ces and service stations, to handle any problems.

J PURCHASE ORDERSFor enquiries and purchase orders, the following details are re-quired:D KSB order No.D No. of general pump assembly drawingD Part item No., description, material, quantity as per drawing

J DISPOSALUsually, mechanical seals can easily be disposed of after a tho-rough cleaning.

D Metal parts (steel, stainless steel, non--ferrous metals),shall be sorted and disposed of in theappropriatewasteme-tal collection facility.

D Plastics (elastomers, PTFE) are special waste. After sor-ting, some of them can be recycled.' CAUTION!Material containing fluorine must not be inci-

nerated.D Ceramic contact facematerials (carbon, ceramics, carbide)

can be separated from their carrier materials and -- beingphysiologically harmless -- disposed of as residual waste.

We reserve the right to technicalmodifications designed toimprove the product, even if they arenotmentioned in thisma-nual yet.

Omega V

33

9 Spare PartsRecommended Spare PartsRecommended spare parts stock for 2 years’ operation to VDMA 24296 (also for continuous operation)

Part no. Description Number of pumps (incl. stand--by pumps)

2 3 4 5 6 8 10and more

Number of spare parts *

234 Impeller 1 1 1 2 2 3 30 %

502 Casing wear ring 4 4 4 6 6 8 50 %

503 Impeller wear ring 4 4 4 6 6 8 50 %

211,940920,932

Shaft with keys and shaft nuts 1 1 2 2 2 3 30 %

321 Rolling element bearing 2 2 4 4 6 8 100 %

524 Shaft protecting sleeve 4 4 4 6 6 8 50 %

461 Packing ring 32 32 48 48 48 64 40 %

411,412421

Set of sealing elements 4 6 8 8 9 12 150 %

433 Mechanical seal Spring--loadedring

4 6 8 8 8 12 90 %

Seat ring 4 6 8 8 8 12 90 %

O--rings 4 6 12 16 16 20 150 %

Seals on 4 6 12 16 16 20 150 %

Seat ring

Set of springs 1 2 2 2 2 4 20 %* These figures already allow for components required twice for replacement

Omega V

34

Interchangeability of rotor components

Pump sizes Pump shaft diameter

40 50 60 70 80 90

80 - 210

80 - 270

80 - 370

100 - 250

100 - 310

100 - 375

*

*

*

*

*

*

125 - 230

125 - 290

125 - 365

125 - 500

150 - 290

150 - 360

*

*

*

*

*

*

150 - 460

150 - 605

200 - 320

200 - 420

*

*

*

*

200 - 520

200 - 670

250 - 370

*

*

*

250 - 480

250 - 600

*

*

300 - 300 *

300 - 435 *

300 - 560

300 - 700

*

*

350 - 360 *

350 - 430

350 - 450

*

*

Omega V

35

10 Forces and Moments

The given forces and moments are mean values forsimultaneous loading in the three planes. If the forces andmoments in one particular direction are larger than given in thetable, consult KSB.

The values given in the table do not apply to the reactionforces of braceless expansion joints.

Dimensions in mm

Pumpsizes

Impeller dimensions in mm Permissible nozzle Mass moments ofinertia J

Permissi-ble opera-

tingpressure

Permissi-ble testpressure

free passage� 10 %

max. diameter Clearances forcesin N

momentsin Nm

(without coupling)in kgm2

in bar in bar

A B C A B C A B C Fx, Fy, Fz1); 3)

Mx, My, Mz1); 3)

withoutwater

withwater

1) 2) 1) 2)

80-210 15 11 -- 215 215 -- 0.30 0.30 -- 800 500 0.023 0.028 16 25 28 37.5

80-270 13 9 -- 275 275 -- 0.30 0.30 -- 800 500 0.037 0.044 16 25 28 37.5

80-370 11 8 -- 345 345 -- 0.30 0.30 -- 800 500 0.027 0.032 16 25 28 37.5

100-250 19 14 -- 254 254 -- 0.35 0.35 -- 1000 700 0.048 0.058 16 25 28 37.5

100-310 15 11 -- 325 325 -- 0.35 0.35 -- 1000 700 0.092 0.110 16 25 28 37.5

100-375 13 10 -- 408 408 -- 0.35 0,35 -- 1000 700 0.229 0.275 16 25 28 37.5

125-230 23 17 -- 245 245 -- 0.35 0.35 -- 1500 1000 0.161 0.193 16 25 28 37.5

125-290 19 12 -- 301 301 -- 0.35 0.35 -- 1500 1000 0.125 0.150 16 25 28 37.5

125-365 14 10 -- 392 392 -- 0.35 0.35 -- 2000 1500 0.261 0.313 16 25 28 37.5

125-500 14 10 -- 482 482 -- 0.35 0.35 -- 2000 1500 0.688 0.825 16 25 28 37.5

150-290 27 20 14 289 289 289 0.45 0.45 0,45 2500 1500 0.169 0.288 16 25 28 37.5

150-360 22 15 -- 355 355 -- 0.45 0.45 -- 2500 2000 0.199 0.338 16 25 28 37.5

150-460 17 12 -- 462 462 -- 0.45 0.45 -- 2500 2000 0.456 0.775 16 25 28 37.5

150-605 16 11 -- 569 569 -- 0.45 0.45 -- 3000 2000 1.074 1.825 24 25 28 37.5

200-320 30 22 17 338 338 338 0.50 0.50 0,50 4000 2750 0.442 0.575 16 25 24 37.5

200-420 26 18 -- 415 415 -- 0.50 0.50 -- 4000 2750 0.588 0.725 16 25 24 37.5

200-520 20 14 -- 540 540 -- 0.50 0.50 -- 4000 2750 1.288 1.675 16 25 24 37.5

200-670 18 12 -- 665 665 -- 0.50 0.50 --4000 2750 3.654 4.750 24 25 28 37.51) see next page2) see next page3) see next page

Omega V

36

Dimensions in mm

Pumpsizes

Impeller dimensions in mm Permissible nozzle Mass moments ofinertia J

Permissi-ble opera-

tingpressure

Permissi-ble testpressure

free passage� 10 %

max. diameter Clearances forcesin N

momentsin Nm

(without coupling)in kgm2

in bar in bar

A B C A B C A B C Fx, Fy, Fz1); 3)

Mx, My, Mz1); 3)

withoutwater

with wa-ter

1) 2) 1) 2)

250-370 39 27 20 390 390 390 0.5 0.5 0,5 4000 2750 0.721 1.225 10 25 15 37.5

250-480 30 20 -- 478 478 -- 0.5 0.5 -- 4000 2750 0.956 1.625 16 25 24 37.5

250-600 23 16 -- 622 622 -- 0.5 0.5 -- 4000 2750 2.206 3.750 24 25 28 37.5

300-300 39 27 -- 323 323 -- 0.5 0.5 -- 4000 3000 0.571 0.800 10 25 15 37.5

300-435 45 32 30 450 450 450 0.6 0.6 0,6 4000 3000 1.785 2.500 10 25 15 37.5

300-560 35 23 -- 553 553 -- 0.6 0.6 -- 5000 3000 2.411 3.375 16 25 24 37.5

300-700 26 18 -- 719 719 -- 0.6 0.6 -- 5000 3000 6.346 8.250 24 25 28 37.5

350-360 39 27 -- 382 382 -- 0.5 0.5 -- 5000 3000 1.116 1.563 10 25 15 37.5

350-430 57 40 -- 430 430 -- 0.6 0.6 -- 5000 3000 2.232 3.125 10 25 15 37.5

350-510 52 36 35 518 518 518 0.6 0,6 0,6 5000 3000 3.393 4.750 10 25 15 37.51) Casing material JL 1040 and GGG-NiCrNb 20 22) Casing material JS 1030 and 1.45173) Casing material JS 1030; 1,4-times the given value4) Casing material 1.4517; 1,9-times the given value

11 Trouble--Shooting11.1 GeneralThe diagram opposite is to facilitate understanding of thecauses of faults and their remedies as indicated in thetrouble--shooting table.The cause of many operating faults on pumps is oftenhydraulic. The hydraulic behavior of a pump is illustrated by itscharacteristic curves H, P, Eta and NPSH in combination withthe plant characteristic curves HA and NPSHA.The operatingpoint B is where the system curve HA and the characteristiccurve H intersect. Consult the manufacturer if the cause of afault is unclear.

PowerHeadEfficiency

Operating Limit

Capacity

Omega V

37

11.2 Trouble--shooting Table

Pum

ppressuretoolow

Pum

ppressuretoohigh

Flowratetoohigh

Flowratetoolow

Pow

erconsum

ptiontoohigh

Pum

pfails

topumpliquidafterbeingsw

itchedon

Pum

pceases

topumpliquid

Pum

pdoes

notrun

smoothly(noise,vibrations)

Inadmissibletemperatureincrease

atpump/

sealcasing

Bearingtemperaturetoohigh

Exessiveleakageatshaftseal

Driveoverloaded

Leakageatpump

Cause Remedy 1)

F F F F F F F F F Operating point B does notlie at the calculated inter-sections of Q and H

Re--adjust operating point

F Pump or piping incomple-tely vented or not primed

Vent.

F F F F F F Suction pipe or impellerblocked

Clean impellerCheck plant for impuritiesRemove deposits in pump and / or pipingCheck strainer / suction opening

F F F Formation of air pockets inthe piping

Correct suction conditionsAlter piping

F F F F F Suction head too high(NPSHavailable too low) /water level too low

Check mode of operationCorrect suction conditionsIncrease positive suction headIncrease back pressure by throttlingInstall pump at a lower levelAlter intake pipe if resistances are too high

F F F F Air is drawn in at shaft seal Clean sealing liquid line, possibly introducesealing liquid from an external source orincrease pressureCheck level of liquid in feed tankReplace shaft sealReplace shaft protecting sleeve

F F F F F Wrong direction of rotation Interchange two phases of the power cableCheck electrical connectionsCheck impeller position, correct ifnecessary

F F F Speed too low Increase speed 1)

Check switchgearFit larger impeller 1)

F F F F Internals worn Check duty point / pump selectionIncrease back pressure by throttlingCheck medium handled for contaminationby chemicals and solids contentReplace worn components

F F Pump pressure is lowerthan specified in the order

Re--adjust operating pointIncrease back pressure by throttling.

1) Consult KSB

Omega V

38

Trouble--shooting Table

Pum

ppressuretoolow

Pum

ppressuretoohigh

Flowratetoohigh

Flowratetoolow

Pow

erconsum

ptiontoohigh

Pum

pfails

topumpliquidafterbeingsw

itchedon

Pum

pceases

topumpliquid

Pum

pdoes

notrun

smoothly(noise,vibrations)

Inadmissibletemperatureincrease

atpump/

sealcasing

Bearingtemperaturetoohigh

Exessiveleakageatshaftseal

Driveoverloaded

Leakageatpump

Cause Remedy 1)

F F Higher density or viscosityof medium handled thanspecified in the order

Reduce speedIn the case of persistent overloading, turndown impeller, if necessary 1)

F F F F F Speed too high Reduce speedIn the case of persistent overloading, turndown impeller, if necessary 1)

F Tie bolts / seals CheckTighten tie boltsReplace gasketsCheck pipe connections and pump moun-ting, if necessary, improve mounting of pi-ping.

F Worn shaft seal Check flushing / sealing liquid pressureclean sealing liquid line, possibly introducesealing liquid from an external source orincrease pressureReplace shaft sealReplace worn componentsReplace shaft protecting sleeve.

F F F F Unfavourable flow tosuction nozzle of pump

Alter pipingIf necessary, alter intake pipe if resistancesare too highCheck whether pipe routing results in twi-sted or irregular flow (e.g. downstream ofan elbow) and correct, if necessary.

1) Consult KSB

Omega V

39

Trouble--shooting Table

Pum

ppressuretoolow

Pum

ppressuretoohigh

Flowratetoohigh

Flowratetoolow

Pow

erconsum

ptiontoohigh

Pum

pfails

topumpliquidafterbeing

switchedon

Pum

pceases

topumpliquid

Pum

pdoes

notrun

smoothly(noise,vibrations)

Inadmissibletemperatureincrease

atpump/

sealcasing

Bearingtemperaturetoohigh

Exessiveleakageatshaftseal

Driveoverloaded

Leakageatpump

Cause Remedy 1)

F F Gland cover, seal covertightened incorrectly,wrong packing material

AlterReplaceCorrectReplace gland packingReplace worn components

F F Lack of cooling liquid orcooling liquid chamber con-taminated

Check flushing / sealing liquid pressureClean sealing liquid line, possibly introducesealing liquid from an external source orincrease its pressureIncrease cooling liquid flowClean cooling liquid line.

F F Pump mis--aligned or reso-nance vibrations in the pi-ping

Re--align pump / driveCheck piping connections and pumpmounting, if necessary, improve mountingof pipingApply vibration--damping measures

F Excessive axial thrust Check duty point / pump selectionCheck mode of operationCheck suction -- side flow.

F Too little, too much or un-suitable lubricant

Clean bearingReplace lubricantTop up, reduce or change lubricant

F F F F Motor is running on twophases only

Replace defective fusesCheck electrical connectionsCheck switchgear.

F F F Rotor is out of balance Clean rotorCheck run--out, straighten if necessaryRe--balance rotor.

F F F Bearings damaged Replace / change

F F Flow rate too low Re--adjust operating pointFully open shut--off valve in the intake pipeFully open shut--off valve in the dischargepipeRecalculate or measure the hydraulic los-ses HV.

1) Consult KSB

Omega V

40

Trouble--shooting Table

Pum

ppressuretoolow

Pum

ppressuretoohigh

Flowratetoohigh

Flowratetoolow

Pow

erconsum

ptiontoohigh

Pum

pfails

topumpliquidafterbeingsw

itchedon

Pum

pceases

topumpliquid

Pum

pdoes

notrun

smoothly(noise,vibrations)

Inadmissibletemperatureincrease

atpump/

sealcasing

Bearingtemperaturetoohigh

Exessiveleakageatshaftseal

Driveoverloaded

Leakageatpump

Cause Remedy 1)

F F In star / delta operationmotor hangs at starstage

Check electrical connectionsCheck switchgear.

F F F Inadmissible air or gascontent in liquid

VentCheck integrity of suction pipe, seal ifnecessary

F F F F F Air drawn in at pumpinlet

Correct suction conditionsReduce flow velocity at suction pipeentryIncrease suction headCheck integrity of suction pipe and seal,if necessaryReplace defective pipes.

F Cavitation (rattling noise) Correct suction conditionsCheck mode of operationIncrease suction headInstall pump at a lower level

F F Foundation not rigidenough

CheckAlter

F F F F F Inadmissible paralleloperation

Re--adjust operating pointAlter pump characteristic H1).

F F Shaft is out of true Renew / Replace

F F F F Impeller rubs against ca-sing components

Check rotorCheck impeller positionCheck that the piping is connectedwithout transmitting any stresses orstrains.

1) Consult KSB

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41

12 Routine Maintenance and Inspection Intervals

Interval Number of per-sonnel required

Time[h]

Maintenance job

Daily 1 1/10

Check leakage on mechanical seal or lea-kage of packed gland(see section 8.1 ”Gland packing”).

Weekly 1 1/4Check pump operation (positive suction pres-sure, total head, bearing temperature, noisesand vibrations)

Monthly1

1

1/4

1/4

Check torsional play of coupling(see section ”Coupling”),If available, switch to stand--by pump or carryout a test run (for 5 min.)

every 20.000operating hours

2 3Replace deep--groove ball bearings (seesection 7.3 ”Dismantling” and7.4 ”Reassembly”).

every 4 years or if totalhead of pump drops 2 6

General inspection and overhaul of pump inaccordance with the operating instructions.

Check and renew, if required:-- wear parts such as: bearings, casing wearring (impeller wear ring, if any), shaftprotecting sleeve

-- impeller and shaft-- Replace sealing elements

Omega V

42

13 Appendix

Types of installation and directions of rotation / flow directions 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-- Foundation (installation DJ) 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-- Foundation (installation DB) 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-- Foundation (installation DK) 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sealing / flushing water piping 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-- Arrangement of sealing water and flush pipes 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flushing line for bottom RESIDUR bearing (1) 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-- Flushing line for Residur bearing (2) 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flushing line for Gland packing (1) 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-- Flushing line for Residur bearing (2) 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-- Flushing line for Residur bearing 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coupling (N--EUPEX) 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General drawing of pump with parts list 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-- Shaft seal: Gland packing DB 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-- Shaft seal: Mechanical seal DB 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical seals, standard design 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical seals, standard design 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shaft seal, mechanical seals – Typ Crane 58U and 58B 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions and weights (modul) 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-- Omega V 80 - 210 up to 150 - 605 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-- Omega V 200 - 320 up to 350 - 510 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General arrangement drawing 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-- Omega V 80 - 210 up to 80 - 370 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-- Omega V 100 - 250 up to 100 - 375 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-- Omega V 125 - 230 up to 125 - 500 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-- Omega V 150 - 290 up to 150 - 605 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-- Omega V 200 - 320 up to 200 – 670 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-- Omega V 250 - 370 up to 250 - 600 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-- Omega V 300 - 300 up to 300 - 700 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-- Omega V 350 - 360 up to 350 - 510 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting device disassembly of upper casing half and pump rotor 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Horizontal

Vertical

Type of installation DB 2) Type of installation DK 2)

2) Depending of motor size

Direction of rotation / flow direction

Horizontal Vertical

Direction of rotationanticlockwise,viewed from the drive end

Direction of rotationclockwise, viewed from thedrive end

Direction of rotationanticlockwise,viewed from the drive end

Direction of rotationclockwise, viewed from thedrive end

Type of installation DJ 2)

Version with intermediate bearing

Pump set with close--coupled motor (type IM B3) 1)

Baseplate, baseframe, coupling guard and motor height adjustment

Type of installation 3E

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43

Types of installation

1) General arrangement drawing ”Pump set 3 E -- Baseplate/baseframe with motor height adjustment” shows the main variants available

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44

Foundation (installation DJ)

Foundation (Foot and Rail)

Part no. Description89-4 Shim182 Foot550 Shim898 Foundation block901 Hex. head bolt593 Rail904 Grub screw920 Nut

Foundation (installation DB)

Foundation (Foot and Motor stool)

Part no. Description89-4 Shim182 Foot341 Motor stool550 Shim531 Locking sleeve898 Foundation block901 Hex. head bolt904 Grub screw920 Nut

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45

Foundation (installation DK)

Foundation (Foot, Motor stool and Support foot)

Part no. Description89-4 Shim182 Foot183 Support foot550 Shim898 Foundation block901 Hex. head bolt904 Grub screw920 Nut

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46

Sealing / flushing water pipingThe pump is equipped with sealing / flushing water piping.These pipes are sheathed PTFE hoses which are flexible,temperature and highly pressure resistant.Another favourable property of PTFE (polytetrafluorethylene)is the extremely low friction coefficient which prevents pipeclogging.Normally we supply this assembly readymounted to the pump.If this is not the case, mount the hoses and fittings as per theattached drawings (see appendix).

Arrangement of sealing water and flush pipes

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47

Flushing line for bottom RESIDUR bearing (1)Flushing line for Residur bearing (2)

(2)(1)

Part no. Description719.01/02 Hose731.02 Double nipple731.04 Double nipple731.05 Bend731.10 T--joint(731.12) Socket

Flushing line for Gland packing (1)Flushing line for Residur bearing (2)

(2) (1)

Part no. Description719.01/02 Hose731.02 Double nipple731.04 Double nipple731.05 Bend731.10 T--joint

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48

Flushing line for Residur bearing

Part no. Description719.02 Hose731.04 Double nipple731.05 Long bend731.09 Short Bend

Caution

Caution

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49

Coupling (N--EUPEX)(Flexible couplings N--EUPEX and N--EUPEX--DS, types Aand ADS)-- N--EUPEX couplings provide radial, angular, axial and

torsional flexibility. They are positive--locking.-- Torque is transmitted by flexible coupling elements

(flexibles).-- The non--linear spring characteristic and the favourable

damping properties of the N--EUPEX coupling effectivelycounteract any dangerous increase in vibrations.

General instructions and safety notesWhen fitting and removing N--EUPEX couplings please notethe following requirements:

D The coupling shall only be operated,serviced or repaired by authorized,skilled and duly qualified staff.

D The coupling shall only be used andoperated within the conditionsstipulated in the technical specificationand supply contract.

D Unauthorized modification and removalofprotectiveequipment is notpermitted.

D Any work on the coupling shall only beperformed with the machine shut down.The driver must be secured againstinadvertent start--up (e.g. by locking thekey--operated switch or removing thepower supply fuses). At the switch--onpoint a notice shall be affixed to theeffect that work is being performed onthe coupling.

D Immediately switch off the driver whenchanges in coupling behaviour occur,such as changed running noises.

D The couplingmust be suitably protectedagainst accidental contact.

Installation-- Design of types A / ADSThe N--EUPEX coupling types A / ADS consist of a couplingpart 1 which houses the flexible coupling blocks (12), the fingerpart 3 and the coupling part 2, which bolts onto part 3.The bolted connection between part 2 and part 3 makes itpossible to separate the coupled machines without axialdisplacement (if clearance P is observed).

S1

Part 1 Part 13Part 12 Part 2

-- Mounting the coupling componentsBefore fitting thecouplingcomponents, carefullyclean theshaftends and the coupling parts. Make sure to remove the flexiblecoupling blocks before cleaning the coupling parts with asolvent.

Heed the manufacturer’s instructions for the use ofsolvents.

Use appropriate tools when pulling on thecoupling parts, to prevent damage to the shaftbearings due to the axial joining force.

Make sure to use suitable lifting tackle.The shaft ends must not protrude from the hub faces. Thecoupling is locked in axial direction by means of the set screwor end plate, as applicable / set screw and end plate,respectively.

The set screws shall only be tightened bymeans of a hexagon socket headwrench toDIN 911, without extension.

Non--compliancewith these instructionsmaycausethe coupling to burst. Danger of life by flyingfragments!

Caution

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50

Heating up the coupling parts (to max. +150 °C) may facilitatepulling on the coupling parts. If temperatures exceed +80 °C,the flexible coupling blocksmust be removed from the couplingparts before the heating process.

Protect against burns from contact with hotcomponents!

If the coupling blocks have been removed, they shall bere--installed after the coupling parts have beenpulled on.Makesure the heated coupling parts have cooled down to under 80°Cbeforedoingso.All couplingblocksusedmustbeof identicalsize and marking.Push the machines to be coupled together.

Take appropriate precautions to prevent injury bycrushing.

Make sure to observe dimension S1. On types A and ADS, theconnection between parts 2 and 3 shall be re--establishedbefore aligning the coupling, and the tightening torque of thescrewed connection between parts 2 and 3 shall be checked(for tightening torques and clearance S1 please refer to point6.6).Aligning the coupling(Also refer to section 5.3.2).The couplings will only tolerate misalignment of the shaft endsto be coupled to a certain extent.When aligning the coupling, the radial and angularmisalignment of the shaft ends should therefore beminimized.With identical operating conditions, the useful life of the flexiblecoupling blocks will be increased as a result.Coupling alignment shall be effected in two planes which arenormal to each other. Use a straight--edge (radialmisalignment) and feeler gauge (angular misalignment) asshown below to verify.

Straight edge

Feeler gauge

Using a dial micrometer will make for increased measuringaccuracy.To allow one shaft end to rotate freely, the driving section canbe separated on types A and ADS by loosening the screwedconnection between parts 2 and 3 and pulling part 3 out of therecesses in part 1.

After the connection has been re--established,check the tightening torque of the bolts.

Caution

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Correlation between tightening torques, dimension P and clearance S1

N-EUPEX N-EUPEX-DS Tightening torque TA and width across flats SW for boltscoupling coupling

g g q A Wto DIN 912 Part 2/3

Size Size TA SW P S1Nm [mm] [mm] [mm]

110 118 14 6 33 2-4125 135 17,5 6 38 2-4140 152 29 8 43 2-4160 172 35 8 47 2-5180 194 44 8 50 2-6200 218 67,5 10 53 2-6225 245 89 10 61 2-6250 272 145 14 69 3-8280 305 185 14 73 3-8315 340 200 14 78 3-8350 350 260 17 83 3-8400 430 340 17 88 3-8440 472 420 17 99 5-10480 514 550 19 104 5-10520 556 670 19 115 5-10560 ---- 710 19 125 6-12610 ---- 1450 22 135 6-12660 ---- 1450 22 145 6-12710 ---- 1450 22 155 6-12

Commissioning the couplingMeasures to be taken prior to commissioningBefore commissioning the coupling check the properinstallation of the flexible coupling elements, i.e.make sure theflexibles are flush with the hub face, and check whether the setscrews are properly tightened. Also verify coupling alignmentand clearance S1 and correct, if necessary. Check whether allscrewed connections have been tightening with the tighteningtorques specified. Finally, fit the coupling guard againstaccidental contact

OperationGeneral operating dataDuring coupling operation, watch out for-- changed running noises,-- sudden vibrations.

If any irregularities occur during operation,switch off the driver immediately and refer to

the trouble--shooting table to determine the cause.

The trouble--shooting table lists possible faults, causes andsuggested remedies.

Caution

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52

Trouble--shootingGeneralThe faults listed below shall serve as orientation only whendetermining failure causes.In a complex plant system, all other components will have to beincluded in the search for possible failure causes.The coupling shall give low--noise and vibration--free operationin all phases of operation. Any other operating behaviour shallbe considered a fault which must be remedied immediately.

Trouble--shooting list

Before commencing any maintenance, repair orother work on the coupling, the operator must shut

down the entire driving mechanism. The drivers, inparticular, must be secured against inadvertent start--up

Also, the accident prevention regulations in force at theinstallation site shall be complied with.

Fault Possible Causes Remedy

Sudden change in noise level and/or Misalignment Shut down the unit.g /sudden vibrations

Eliminate cause for misalignment, if any.g , y(E.g. re--tighten the foundation bolts).Inspect for wear proceed as describedInspect for wear, proceed as describedin section ”Coupling -- Maintenance and Repair”in section Coupling -- Maintenance and Repair

Flexibles are worn Shut down the unit.

Torque transmission bymetal to metal contact

Dismantle the coupling and remove what is left of theflexible coupling blocksmetal--to--metal contact flexible coupling blocks.

Inspect the coupling parts and replaceany damaged components.any damaged components.

C li bl k h ll l b l d b lCoupling blocks shall always be replaced by completesets of new coupling blocks; only use.sets of new coupling blocks; only use.coupling blocks with identical markings.

Verify alignment and correct, if necessary.y g , y

Check the tightening torques of the screwed connec-Check the tightening torques of the screwed connec-tion between parts 2 and 3.

Maintenance and repairGeneralThe torsional play between the two coupling parts shall bechecked in acc.with themaintenance schedule of the plant, butat least once a year.If torsional play must not be limited for extremely smoothcoupling operation, the plastic flexibles can be allowed to weardown to approx. ¼ of their original thickness before they haveto be replaced. To assess the wear condition of the couplingblocks, the table below indicates the permissible torsional playas indicated by the chord dimension �SV on the outsidecoupling diameter.

To determine the chord dimension�SV, rotate one coupling partby hand up to the stop and mark the coupling parts (seeillustration). Hand--rotate one coupling part into the oppositedirection up to the stop. The two marks will diverge. Thedistance between the marks is the chord dimension �SV. If �SVexceeds the value given in the table, the flexible couplingblocks have to be replaced.

Coupling blocks shall always be replacedby complete sets of new coupling blocks;only use coupling blocks with identicalidentification numbers.

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Table: Wear mark on N-EUPEX-couplingSize 58 68 80 95 110 125 140 160 180 200 225 250 280 315 350 400 440 480 520 560 610 660 710

Wear-mark�SV

5.5 5.5 5.0 6.0 7.0 8.0 8.0 8.0 8.0 8.5 9.0 10.0 11.5 10.5 11.5 13.0 14.0 15.5 17.5 17.5 19.5 21.0 22.5

Table: Wear mark on N-EUPEX-DS-couplingSize 66 76 88 103 118 135 152 172 194 218 245 272 305 340 380 430 472 514 556

Wear-mark�SV

6.0 7.0 5.0 7.0 9.0 10.5 11.5 9.0 8.0 7.0 6.5 7.0 8.0 6.5 7.0 10.0 12.0 14.0 16.0

Replacing wear partsUse only genuine N--EUPEX flexible blocks as spare parts, toensure correct torque transmissionand trouble--freeoperation.Please note:On typesAandADS, the flexibles canbe replacedwithout axialdisplacement of the coupled machines

After the screwed connection between parts 2 and 3 has beenundone, part 3 can be shifted in axial direction. By rotating part3, the flexible coupling blocksare freely accessible. To facilitateaxial displacement, sizes 225--430 are provided with forcingthreads in part 1. Fromsize 440, the forcing threads are locatedin part 3 (see illustrations).

For reassembly carefully follow the instructions in the sectionson ”Installation” and ”Commissioning”.

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54

General drawing of pump with parts list Shaft seal: Gland packing / DB

Special adhesive 2503/L28 Desmodur

Sealed with Loctite 574

ALTEMP Q NB 50 grease

Shaftdiameter

Axial overhang of shaft protectingsleeve

dW A � 0.540 450 2.560 270 280 390 2

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55

Part no. Description Part no. Description Part no. Description

102 Volute casing 421 Radial shaft seal ring 550 Washer

105.01 Lower casing half 441 Housing for shaft seal 561 Grooved pin

105.02 Upper casing half 452 Gland cover 719 Hose

160 Cover 455 Gland packing 901 Hex. head bolt

182 Foot 457 Stuffing box insert 902 Stud

211 Pump shaft 458 Neck ring 903 Screwed plug

234 Impeller 461 Lantern ring 904 Grub screw

321 Deep groove ballbearing

502 Casing wear ring 914 Socket head cap screw

341 Motor stool 503 Impeller wear ring 920 Nut

350 Bearing housing 524 Shaft protecting sleeve 930 Safety device

360 Bearing cover 525 Spacer sleeve 932 Circlip

411 V-ring 531 Locking sleeve 940 Key

412 O-ring 545 Bearing bush 950 Cup spring

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56

General drawing of pump with parts list Shaft seal: Mechanical seal / DB

Glued in with Loctite 2701

Special adhesive 2503/L28 Desmodur

A Sealed with Loctite 574

ALTEMP Q NB 50 grease

Shaftdiameter

Axial overhang of shaft protectingsleeve

dW A � 0.540 450 2.560 270 280 390 2

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57

Part no. Description Part no. Description Part no. Description

102 Volute casing 421 Radial shaft seal ring 719 Hose

105.01 Lower casing half 433 Mechanical seal 901 Hex. head bolt

105.02 Upper casing half 441 Housing for shaft seal 902 Stud

160 Cover 457 Neck ring 903 Screwed plug

182 Foot 458 Lantern ring 904 Grub screw

211 Pump shaft 502 Casing wear ring 914 Socket head cap screw

234 Impeller 503 Impeller wear ring 920 Nut

321 Deep groove ballbearing

524 Shaft protecting sleeve 930 Safety device

341 Motor stool 525 Spacer sleeve 932 Circlip

350 Bearing housing 531 Locking sleeve 940 Key

360 Bearing cover 545 Bearing bush 950 Cup spring

411 V-ring 550 Washer

412 O-ring 561 Grooved pin

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Mechanical seals, standard designStandardized mechanical seal to DIN 24960 -- short design, non--balancedSizes for shaft diameter dw = 40 to 80 mm (with single spring)

Ødw

211 525.02 411457.02524.01 433 901.16471

Flushing lineconnection

Standardized mechanical seal to DIN 24960 -- short design, non--balancedSizes for shaft diameter dw = 90 mm (with multiple spring arrangement)

�110

dw=90

211 525.02 411457.02524.01 433 901.16471Flushing lineconnection

Part no. Description Part no. Description211 Pump shaft 471 Seal cover433 Mechanical seal 524.01 Shaft protecting sleeve441 Housing for shaft seal 525.02 Spacer sleeve457.02 Neck ring 901.16 Hex. head bolt

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59

Mechanical seals, standard designBalanced mechanical seal (for operating pressures > 16 bar) to DIN 24960Sizes for shaft diameter dw = 40 to 80 mm (with covered spring

Flushing line connection

dw

211

525.02

411457.02

524.01

433 901.16471

Balanced mechanical seal (for operating pressures p > 16 bar) to DIN 24960Sizes for shaft diameter dw = 90 mm (with multiple spring arrangement)

�110

dw=90

211 525.02 411457.02524.01 433 901.16471Flushing lineconnection

Part no. Description Part no. Description

211 Pump shaft 471 Seal cover

433 Mechanical seal 524.01 Shaft protecting sleeve

441 Housing for shaft seal 525.02 Spacer sleeve

457.02 Neck ring 901.16 Hex. head bolt

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Shaft seal -- mechanical seals -- Type Crane 58U and 58BDescriptionThe mechanical seals, 58U and 58B, are precision--made andmust be treated accordingly. The contact faces are lapped toa high degree of accuracy and prior to despatch they arecovered in a protective sleeve to prevent damage. If theprotective sleeve is removed for installation purposes, thengreat care must be taken to avoid any damage to the finelyfinished, lapped surfaces.Whenever replacing worn out or damaged mechanical seals,the section of the shaft or sleeve whichwill accept the new sealmust be cleaned and oiled.

Preparation for installation1. The installation dimensions and tolerances must comply

with those outlined in the relevant literature.2. The cover which will accept the seat ring must be checked

with regard to depth and installation dimensions.

780 Retainer 578 Balanced face305 Grub screw 096 Snap ring582 (092) Spring 500 Seat type BP583 Thrust ring 501 Seat ring123 O-ring 902 Seat type BO574 Rotating face 123 (R) O-ring564 Support ring

Installation and operation1. Clean and lightly lubricate the shaft / sleeve with a suitable

lubricant.Attention:

Sealingelementsmanufactured inEP--Elastomermaterialsmust not come in contact with mineral oil and grease.

2. Push on the rotating unit applying light manual pressure.

3. Push the seat ring together with the joint ring into the coverapplying evenmanual pressure. The joint ring shall also belubricated using a suitable lubricant.

4. The contact faces must be cleaned prior to installation intothemachine.Tighten thecoverboltsevenly. Overtighteningcan affect the true running of the rubbing faces andtherefore have an adverse effect on the functioning of themechanical seal.

5. Manually turn the shaft. Fill the machine whilstsimultaneouslymonitoring theventingequipmentwithin theseal area. Check the circulation pipe.

Caution

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Dismantling and assembly of the rotating unitThe first step is to remove the snap ring (096) from the retainer(780). The springs are compressed to achieve this. This canbe done by using a simple tool, as illustrated.

Lapped surfaces of the rotating face must beprotected.

Wing nut

Thrust plate with glued--on

protective support

Locking nut

Baseplate

Grub screw

1. The rotating face (574 / 578) is pushed down and the snapring (096) is removed from the groove using a pointed tool.

2. Now remove in the following sequence: the rotating face(574 / 578), the O--ring (123), the thrust ring (583) and thesprings (582 / 092).

Assembly is carried out in reverse sequence.The following must be noted during assembly:The drive cams in the retainer (780) must engage into thegrooves of the thrust ring (583) or the rotating face (574 / 578).Fit the snap ring (096) into the groove of the retainer (780),leavingoneendof thesnap ringprotrudingbyapprox6 -- 12mmto the side of the drilled hole

At the outer circumference of the retainer (780) there are 2marker grooves. The lower one runs precisely through thecentre of the drilled hole for the internal socket head screws,which indicates that the thread of the screws is metric.The upper groove assists during installation. If the initialtension of themechanical seal is set correctly to the installationlength, then the thrust ring shall be in alignment (be flush) withthis groove.

z

s1 s2

d1

5D

ll

h 5

h 4

6B6B

A B

Section A - B

m4

m6

m5

m3 h 2

DN1

1M 1M

DN2

n6

n5

h 3

a1 a2

Direction of rotation:CLOCKWISE

Keyway and key toDIN 6885 sheet 1Shaft diameter:Tolerance h6 to DIN 7155

Connections:- 1M Pressure gauge G 1/2- 5D Vent G 1/2- 6B Drainage G 1/2- 8B Leakage liquid drain G 3/4

Flanges:- Flat surface flanges- Flange thickness to ANSI- Connect pipes without stress

only for Omega V 150-605

z2 x--holes d2

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62

Table of dimensions Omega V 80 -- 210 up to 150 - 605N.B.: If the pump’s direction of rotation

is ANTI--CLOCKWISE, the position ofthe suction and discharge nozzle is reversed(mirror image).

Major external pump dimensions all dimensions in mm

Pump Flange dimensions Pump dimensionssize DN1 DN2 s1 s2 a1 a2 h2 h3 h4 h5 z 1) z2 d280-210

300 300168 340

80-270 125 80 35 29 300 300 140 190 300 715 380

80-370 330 330 225 450100-250

330 330195 390

100-310 150 100 37 32330 330

170 225 300 715 450

100-375 370 370 260 520125-230 210 420 4 18125-290

200 125 41 35370 370

200230

355 870460

125-365200 125 41 35 200

260355 870

520125-500 450 450 305 610150-290

400 400245

355 870490

150-360200 150 41 37

400 400200 265

355 870530

150-460200 150 41 37

450 450 305400 990

610

150-605 600 500 300 370400 990

740 6 181) z = the dimensions to be maintained around the casing cover for dismantling of the rotor

k

d2

numberof holes n

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63

Major external pump dimensions and weights all dimensions in mm

Pump Foot dimensions Shaft Weights [kg]size m3 m4 m5 m6 n5 n6 d1 l1 Pump Water

content

80-210 185 1080-270 640 275 100 380 450 340 35 80 195 1580-370 205 20100-250 210 20100-310 695 315 115 420 500 400 35 80 225 25100-375 245 30125-230 250 35125-290

855 360 210 475 600 450 45 100275 40

125-365 855 360 210 475 600 450 45 100 300 45125-500 700 560 335 55150-290

600 450 45 100350 50

150-360 855 360 210 475600 450 45 100

360 60

150-460 700 56055 125

440 75

150-605 1060 460 315 575 900 70055 125

650 90

Standard flange design 1):

Pumpsize

JL 1040 / GGG-NiCrNb 202Nominal pressure acc. to:

JS 1030 / 1.4517Nominal pressure acc. to:

DIN 2501ISO 7005/2

BS 4504 ANSI B 16.1 DIN 2501ISO 7005/2

BS 4504 ANSI B 16.1

80-21080-270 PN 16 Table 16/11 Class 250 PN 25 Table 25/11 Class 25080-370100-250100-310 PN 16 Table 16/11 Class 250 PN 25 Table 25/11 Class 250100-375125-230

125-290PN 16 Table 16/11 Class 250 PN 25 Table 25/11 Class 250

125-365PN 16 Table 16/11 Class 250 PN 25 Table 25/11 Class 250

125-500

150-290

150-360 PN 16 Table 16/11Class 250 PN 25 Table 25/11 Class 250

150-460Class 250 PN 25 Table 25/11 Class 250

150-605 PN 25 Table 25/111) Other flange designs are available on request

Flange dimensions -- Drilling diagram all dimensions in mm

Standard DN 80 DN 100 DN 125 DN 150 DN 200d2 k n d2 k n d2 k n d2 k n d2 k n

ISO 7005/2DIN 2501 PN 16 19 160 8 19 180 8 19 210 8 23 240 8 23 295 12

ISO 7005/2DIN 2501 PN 25 19 160 8 23 190 8 28 220 8 28 250 8 28 310 12

BS 4504 Table 16/11 19 160 8 19 180 8 19 210 8 23 240 8 23 295 12BS 4504 Table 25/11 19 160 8 23 190 8 28 220 8 28 250 8 28 310 12ANSI B 16.1 Class 250 23 168 8 23 200 8 23 235 8 23 270 12 28 330 12

z

s1 s2

d1

5D

ll

h 5

h 4

6B6B

A B

Section A - B

m4

m6

m5

m3 h 2

DN1

1M 1M

DN2

n6

n5

h 3

a1 a2

Direction of rotation:CLOCKWISE

Keyway and key toDIN 6885 sheet 1Shaft diameter:Tolerance h6 to DIN 7155

Connections:- 1M Pressure gauge G 1/2- 5D Vent G 1/2- 6B Drainage G 1/2- 8B Leakage liquid drain G 3/4

Flanges:- Flat surface flanges- Flange thickness to ANSI- Connect pipes without stress

only for Omega V 150-605

z2 x--holes d2

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64

Table of dimensions Omega V 200 -- 320 up to 350 - 510N.B.: If the pump’s direction of rotation

is ANTI--CLOCKWISE, the position ofthe suction and discharge nozzle is reversed(mirror image).

Major external pump dimensions all dimensions in mm

Pump Flange dimensions Pump dimensionssize DN1 DN2 s1 s2 a1 a2 h2 h3 h4 h5 z 2) z2 d2

200-320 450 450240

285400 990

570

200-420250 200 48 41

500500

240 310 400 990 620 6 18

200-520 250 200 48 41 600500

300 370440 1095

740

200-670 650 550 350 430440 1095

860

250-370 33 (51) 1) 32 (48) 1) 500 500300

320 440 1095 640

250-480 300 25051 48

550550

300355

500 1230710

250-60051 48

650550

350 415500 1230

830

300-300 350 36 (54) 1) 33 550 500 300 360 440 1095 720 6 22

300-435300

38 (57) 1) (51) 1) 650 550 350 365 500 1230 730

300-560 400300

57 51700

650350 430

570 1380860

300-70057 51

750650

400 480570 1380

960

350-360 400 38 (57) 1) 650 550 350 410 500 1230 820350-430 450 350 41 (60) 1) 36 (54) 1) 750

650 400465

570 1380930

350-510 400350

38 (57) 1)36 (54)

700650 400

420570 1380

8401) For casing material GGG-NiCrNb 202, JS 1030, 1.45172) z = the dimensions to be maintained around the casing cover for dismantling of the rotor

k

d2

numberof holes n

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65

Major external pump dimensions and weights all dimensions in mm

Pump Foot dimensions Shaft Weights [kg]size m3 m4 m5 m6 n5 n6 d1 l1 Pump Water

content

200-3201060 460 575 700 560 55 125

450 80

200-420 1060 460

315

575 700 560 55 125 520 95

200-520 1120 520 315 635900 700 65 140

840 115

200-670 1180 560 685900 700 65 140

990 140

250-3701180 560 685

65 140 665 125

250-4801180 560

315685

900 70075 160

830 145

250-600 1210 590 71575 160

1215 180

300-300 1210 590315

715900 700

65 160 630 100

300-435 1250 630315

755900 700

75 160 905 190

300-560 1375 670400

7951200 950 85 180

1425 225

300-700 1415 710400

8351200 950 85 180

1690 275

350-360 1250 630 315 755 900 700 75 160 865 160350-430

1415 710 400 835 1200 950 85 1801285 240

350-5101415 710 400 835 1200 950 85 180

1395 290

Standard flange design 1):

Pumpsize

JL 1040 / GGG-NiCrNb 202Nominal pressure acc. to:

JS 1030 / 1.4517Nominal pressure acc. to:

DIN 2501ISO 7005/2

BS 4504 ANSI B 16.1 DIN 2501ISO 7005/2

BS 4504 ANSI B 16.1

200-320 Table 16/11

200-420 PN 16Class 250 PN 25 Table 25/11 Class 250200-520 Class 250 PN 25 Table 25/11 Class 250

200-670 PN 25 Table 25/11

250-370 PN 10 Table 10/11 Class 125

250-480 PN 16 Table 16/11Class 250

PN 25 Table 25/11 Class 250

250-600 PN 25 Table 25/11Class 250

300-300PN 10 Table 10/11 Class 125

300-435PN 10 Table 10/11 Class 125

PN 25 Table 25/11 Class 250300-560 PN 16 Table 16/11

Class 250

PN 25 Table 25/11 Class 250

300-700 PN 25 Table 25/11Class 250

350-360

350-430 PN 10 Table 10/11 Class 125 PN 25 Table 25/11 Class 250

350-5101) Other flange designs are available on request

Flange dimensions -- Drilling diagram all dimensions in mmStandard DN 200 DN 250 DN 300 DN 350 DN 400 DN 450

d2 k n d2 k n d2 k n d2 k n d2 k n d2 k n

ISO 7005/2DIN 2501 PN 10 23 295 8 23 350 12 23 400 12 23 460 16 28 515 16 28 565 20

ISO 7005/2DIN 2501 PN 16 23 295 12 28 355 12 28 410 12 28 470 16 31 525 16 31 585 20

ISO 7005/2DIN 2501 PN 25 28 310 12 31 370 12 31 430 16 34 490 16 37 550 16

BS 4504 Table 10/11 23 295 8 23 350 12 23 400 12 23 460 16 28 515 16 28 565 20BS 4504 Table 16/11 23 295 12 28 355 12 28 410 12 28 470 16 31 525 16 31 585 20BS 4504 Table 25/11 28 310 12 31 370 12 31 430 16 34 490 16 37 550 16ANSI B 16.1 Class 125 23 299 8 28 362 12 28 432 12 28 476 12 28 540 16 31 578 16ANSI B 16.1 Class 250 28 330 12 28 387 16 31 451 16 31 514 20 34 572 20 34 629 24

Direction of rotation:CLOCKWISE

Type of arrangement DB Type of arrangement DK

Grouting

h 7

X

A B

s1

h 6h 5

h 4

6B

5D

6B

5

s2

270170

250

a1 a2

1M

DN2 m6

m3

n5

Section A - B

View X

n6

m4

m5

1M

h 2

h 3

Z

DN1

Flanges:- Flat surface flanges- Flange thickness to ANSI- Connect pipes without stress

Connections:- 1M Pressure gauge G 1/2- 5D Vent G 1/2- 6B Drainage G 1/2- 8B Leakage liquid drain G 3/4

Position of the terminal box to be in accordancewith motor dimension sheet

Omega V

66

General arrangement drawing Omega V 80 -- 210 up to 80 -- 370

Major external pump dimensions and weights all dimensions in mmPump size Flange dimensions Pump dimensions Weights [kg]

DN1 DN2 s1 s2 a1 a2 h2 h3 h4 h5 z 1) Pump Watercontent

80-210300 300

168 340 185 10

80-270 125 80 34 29 300 300 140 190 300 715 380 195 15

80-370 330 330 225 450 205 201) z = the dimensions to be maintained around the casing cover for dismantling of the rotor

k

d2

numberof holes n

Omega V

67

Standard flange design 1):

Pumpsize

JL 1040 / GGG-NiCrNb 202Nominal pressure acc. to:

JS 1030 / 1.4517Nominal pressure acc. to:

DIN 2501ISO 7005/2

BS 4504 ANSI B 16.1 DIN 2501ISO 7005/2

BS 4504 ANSI B 16.1

80-210

80-270 PN 16 Table 16/11 Class 250 PN 25 Table 25/11 Class 250

80-3701) Other flange designs are available on request

Flange dimensions -- Drilling diagram all dimensions in mmStandard Suction flange Discharge flange

DN 125 DN 80

d2 k n d2 k n

ISO 7005/2DIN 2501

PN 16 19 210

ISO 7005/2DIN 2501

PN 25 28 2208

19 1608

BS 4504 Table 16/11 19 2108 8

BS 4504 Table 25/11 28 220

ANSI B 16.1 Class 250 23 235 23 168

Motor dimensions and weights IEC-Motors, IP 55 2) all dimensions in mm

Pump size Type ofarrangement

Motor size c1 h6 h7 m3 m4 m5 m6 n5 n6 Weightof motor

DB DK [kg]

�

min. 100 L 250 780 315640

15

80 210� ---- max. 200 L 400

830665 640 450 250

80-210---- �

min. 225 M 450830

695720

330---- �

max. 250 M 550 860 790720

710 435

� ----min. 100 L 250 780 315

640 275 100 380 34025

80-270� ----

max. 200 L 400830

665640 275 100 380 450 340 250

80-270

---- �

min. 225 M 450830

695720

330---- �

max. 315 S 660 860 970720

710 830

80-370 � ----min. 132 S 300 800 375

64045

80-370 � ----max. 200 L 400 830 665

640450 250

2) Dimension and weight deviations subject to selected motor manufacturer are to be considered

Direction of rotation:CLOCKWISE

Type of arrangement DB Type of arrangement DK

Grouting

h 7

X

A B

s1

h 6h 5

h 4

6B

5D

6B

5

s2

270170

250

a1 a2

1M

DN2 m6

m3

n5

Section A - B

View X

n6

m4

m5

1M

h 2

h 3

Z

DN1

Flanges:- Flat surface flanges- Flange thickness to ANSI- Connect pipes without stress

Connections:- 1M Pressure gauge G 1/2- 5D Vent G 1/2- 6B Drainage G 1/2- 8B Leakage liquid drain G 3/4

Position of the terminal box to be in accordancewith motor dimension sheet

Omega V

68

General arrangement drawing Omega V 100 -- 250 up to 100 - 375

Major external pump dimensions and weights all dimensions in mmPump size Flange dimensions Pump dimensions Weights ( [kg]

DN1 DN2 s1 s2 a1 a2 h2 h3 h4 h5 z 1) Pump Watercontent

100-250330 330

195 390 210 20

100-310 150 100 37 32 330 330 170 225 300 715 450 225 25

100-375 370 370 260 520 245 301) z = the dimensions to be maintained around the casing cover for dismantling of the rotor

k

d2

numberof holes n

Omega V

69

Standard flange design 1):

Pumpsize

JL 1040/ GGG-NiCrNb 202Nominal pressure acc. to:

JS 1030 / 1.4517Nominal pressure acc. to:

DIN 2501ISO 7005/2

BS 4504 ANSI B 16.1 DIN 2501ISO 7005/2

BS 4504 ANSI B 16.1

100-250

100-310 PN 16 Table 16/11 Class 250 PN 25 Table 25/11 Class 250100-375

1) Other flange designs are available on request

Flange dimensions -- Drilling diagram all dimensions in mmStandard Suction flang Discharge flange

DN 150 DN 100

d2 k n d2 k n

ISO 7005/2DIN 2501 PN 16 23 240 19 180

ISO 7005/2DIN 2501 PN 25 28 250 8 23 190 8

BS 4504 Table 16/11 23 240 19 180

BS 4504 Table 25/11 28 25023

190

ANSI B 16.1 Class 250 23 270 1223

200

Motor dimensions and weights IEC-Motors, IP 55 2) all dimensions in mm

Pump size Type ofarrangement

Motor size c1 h6 h7 m3 m4 m5 m6 n5 n6 Weightof motor

DB DK [kg]

�

min. 100 L 250 780 315695 500

25

100 250� ---- max. 225 M 450 830 695 695 500 330

100-250---- �

min. 250 M 550860

790760 810

435---- �

max. 315 M 660860

970760 810

850

� ----min. 132 M 300 800 375

695 50055

100-310� ----

max. 225 M 450 830 695695 500

330100-310

---- �

min. 250 M 550860

790760

315 115 420810

400 435---- �

max. 315 800860

1230760 810

1500

� ----min. 160 M 350

830481

695 50075

100-375� ----

max. 225 M 450830

695695 500

330100-375

---- �

min. 250 M550 860

790760 810

435---- �

max. 280 S550 860

865760 810

6102) Dimension and weight deviations subject to selected motor manufacturer are to be considered

Direction of rotation:CLOCKWISE

Type of arrangement DB Type of arrangement DK

Grouting

h 7

X

A B

s1

h 6h 5

h 4

6B

5D

6B

5

s2

270170

250

a1 a2

1M

DN2 m6

m3

n5

Section A - B

View X

n6

m4

m5

1M

h 2

h 3

Z

DN1

Flanges:- Flat surface flanges- Flange thickness to ANSI- Connect pipes without stress

Connections:- 1M Pressure gauge G 1/2- 5D Vent G 1/2- 6B Drainage G 1/2- 8B Leakage liquid drain G 3/4

Position of the terminal box to be in accordancewith motor dimension sheet

Omega V

70

General arrangement drawing Omega V 125 - 230 up to 125 -- 500

Major external pump dimensions and weights all dimensions in mmPump size Flange dimensions Pump dimensions Weights [kg]

DN1 DN2 s1 s2 a1 a2 h2 h3 h4 h5 z 1) Pump Watercontent

125-230 210 420 250 35

125-290200 125 41 35

370 370200

230355 870

460 275 40

125-365 200 125 41 35 200 260 355 870 520 300 45

125-500 450 450 305 610 335 551) z = The dimensions to be maintained around the casing cover for dismantling of the rotor

k

d2

numberof holes n

Omega V

71

Standard flange design 1):

Pumpsize

JL 1040 / GGG-NiCrNb 202Nominal pressure acc. to:

JS 1030 / 1.4517Nominal pressure acc. to:

DIN 2501ISO 7005/2

BS 4504 ANSI B 16.1 DIN 2501ISO 7005/2

BS 4504 ANSI B 16.1

125-230125-290

PN 16 Table 16/11 Class 250 PN 25 Table 25/11 Class 250125-365 PN 16 Table 16/11 Class 250 PN 25 Table 25/11 Class 250

125-5001) Other flange designs are available on request

Flange dimensions -- Drilling diagram all dimensions in mmStandard Suction flange Discharge flange

DN 200 DN 125d2 k n d2 k n

ISO 7005/2DIN 2501 PN 16 23 295 19 210

ISO 7005/2DIN 2501 PN 25 28 310

1228 220

8BS 4504 Table 16/11 23 295

1219 210

8

BS 4504 Table 25/11 28 310 28 220

ANSI B 16.1 Class 250 28 330 23 235

Motor dimensions and weights IEC-Motors, IP 55 2) all dimensions in mmPump size Type of

arrangementMotor size c1 h6 h7 m3 m4 m5 m6 n5 n6 Weight

of motor

DB DK [kg]

�

min. 132 S 300 955 415855 600

45

125 230� ---- max. 280 M 550 865 855 600 660

125-230---- �

min. 315 S660

1015970 820 860

830---- �

max. 315 M660 970 820 860

850

� ----min. 132 M 300 955 415

855 600 45055

125-290� ----

max. 280 M 550 865855 600 450 660

125-290

---- �

min. 315 S 660 1015 970905

360 210 475920

830---- �

max. 315 800 1230905 920

1500

125-365 � ----min. 160 L 350 985 525

60090

125-365 � ----max. 280 M 550 1015 865

855

600660

125-500 � ----min. 200 L 400 985 610

855

700 560170

125-500 � ----max. 315 M 660 1045 970

700 560910

2) Dimension and weight deviations subject to selected motor manufacturer are to be considered

Direction of rotation:CLOCKWISE

Type of arrangement DB Type of arrangement DK

Grouting

only forpump size 150-605

h 7

X

A B

s1

h 6h 5

h 4

6B

5D

6B

5

s2

270170

250

a1 a2

1M

DN2 m6

n5

Section A - B

View X

n6

m4

m5

1M

h 2

h 3

Z

DN1

m3

Flanges:- Flat surface flanges- Flange thickness to ANSI- Connect pipes without stress

Connections:- 1M Pressure gauge G 1/2- 5D Vent G 1/2- 6B Drainage G 1/2- 8B Leakage liquid drain G 3/4

Position of the terminal box to be in accordancewith motor dimension sheet

Omega V

72

General arrangement drawing Omega V 150 -- 290 up to 150 -- 605

Major external pump dimensions and weights all dimensions in mmPump size Flange dimensions Pump dimensions Weights [kg]

DN1 DN2 s1 s2 a1 a2 h2 h3 h4 h5 z 1) Pump Watercontent

150-290400 400

245355 870

490 350 50

150-360200 150 41 37

400 400 200 265 355 870 530 360 60

150-460 200 150 41 37 450 450 305400 990

610 440 75

150-605 600 500 300 370400 990

740 650 901) z = the dimensions to be maintained around the casing cover for dismantling of the rotor

k

d2

numberof holes n

Omega V

73

Standard flange design 1):

Pumpsize

JL 1040 / GGG-NiCrNb 202Nominal pressure acc. to:

JS 1030 / 1.4517Nominal pressure acc. to:

DIN 2501ISO 7005/2

BS 4504 ANSI B 16.1 DIN 2501ISO 7005/2

BS 4504 ANSI B 16.1

150-290

150-360 PN 16 Table 16/11Class 250 PN 25 Table 25/11 Class 250150-460 Class 250 PN 25 Table 25/11 Class 250

150-605 PN 25 Table 25/111) Other flange designs are available on request

Flange dimensions -- Drilling diagram all dimensions in mm

Standard Suction flange Discharge flange

DN 200 DN 150

d2 k n d2 k n

ISO 7005/2DIN 2501 PN 16 23 295 23 240

ISO 7005/2DIN 2501 PN 25 28 310

1228 250 8

BS 4504 Table 16/11 23 29512

23 240

BS 4504 Table 25/11 28 310 28 250

ANSI B 16.1 Class 250 28 330 23 270 12

Motor dimensions and weights IEC-Motors, IP 55 2) all dimensions in mm

Pump size Type ofarrangement

Motor size c1 h6 h7 m3 m4 m5 m6 n5 n6 Weightof motor

DB DK [kg]

150 290 �

min. 160 L 350 985 485 93150-290 � ---- max. 225 M 450 1015 695

600 450330

150-360 � ----min. 160 L 350 985 485

855 360 210 475

600 450 90150-360 � ----

max. 280 M 550 1015 695 855 360 210 475 660

150-460 � ----min. 200 L 400 1105 665

700 560240

150-460 � ----max. 315 L 660 1165 1110

700 5601200

150-605 � ----min. 280 S 550 1135 865

1060 460 315 575 900 700610

150-605 � ----max. 355 900 1165 1455

1060 460 315 575 900 7002200

2) Dimension and weight deviations subject to selected motor manufacturer are to be considered

Direction of rotation:CLOCKWISE

Type of arrangement DB Type of arrangement DK

Grouting

h 7

X

A B

s1

h 6h 5

h 4

6B

5D

6B

5

s2

270170

250

a1 a2

1M

DN2 m6

n5

Section A - B

View X

n6

m4

m5

1M

h 2

h 3

Z

DN1

m3

Flanges:- Flat surface flanges- Flange thickness to ANSI- Connect pipes without stress

Connections:- 1M Pressure gauge G 1/2- 5D Vent G 1/2- 6B Drainage G 1/2- 8B Leakage liquid drain G 3/4

Position of the terminal box to be in accordancewith motor dimension sheet

Omega V

74

General arrangement drawing Omega V 200 -- 320 up to 200 -- 670

Major external pump dimensions and weights all dimensions in mmPump size Flange dimensions Pump dimensions Weights (kg)

DN1 DN2 s1 s2 a1 a2 h2 h3 h4 h5 z 1) Pump Watercontent

200-320 450 450240

285400 990

570 450 80

200-420250 200 48 41

500500

240 310 400 990 620 520 95

200-520 250 200 48 41 600500

300 370440 1095

740 840 115

200-670 650 550 350 430440 1095

860 990 1801) z = the dimensions to be maintained around the casing cover for dismantling of the rotor

k

d2

numberof holes n

Omega V

75

Standard flange design 1):

Pumpsize

JL 1040 / GGG-NiCrNb 202Nominal pressure acc. to:

JS 1030 / 1.4517Nominal pressure acc. to:

DIN 2501ISO 7005/2

BS 4504 ANSI B 16.1 DIN 2501ISO 7005/2

BS 4504 ANSI B 16.1

200-320

200-420 PN 16 Table 16/11Class 250 PN 25 Table 25/11 Class 250200-520 Class 250 PN 25 Table 25/11 Class 250

200-670 PN 25 Table 25/111) Other flange designs are available on request

Flange dimensions -- Drilling diagram all dimensions in mm

Standard Suction flange Discharge flange

DN 250 DN 200

d2 k n d2 k n

ISO 7005/2DIN 2501 PN 16 28 355 23 295

ISO 7005/2DIN 2501 PN 25 31 370 12 28 310

12BS 4504 Table 16/11 28 355 23 295

12

BS 4504 Table 25/11 31 370 310

ANSI B 16.1 Class 250 28 387 16 28 330

Motor dimensions and weights IEC-Motors, IP 55 2) all dimensions in mm

Pump size Type ofarrangement

Motor size c1 h6 h7 m3 m4 m5 m6 n5 n6 Weightof motor

DB DK [kg]

200 320 �

min. 180 L 350 1105 995 180200-320 � ---- max. 280 M 550 1135 865

1060 460 575 700 560660

200-420 � ----min. 200 L 400 1105 665 1060 460 575 700 560 240

200-420 � ----max. 315 L 660 1135 1110 1200

200-520 � ----min. 250 M 550 1200 790

1120 520 315 635435

200-520 � ----max. 355 900 1455

1120 520 315 635900

2200

� ----min. 315 S 660 1270 1110

1180 560900

700830

200-670� ----

max. 355 9001270

14551180 560

685700

2200200-670

---- �

min.400 1000 1310 1615 1220 560

6851160 3200---- � max.

400 1000 1310 1615 1220 560 1160 3200

2) Dimension and weight deviations subject to selected motor manufacturer are to be considered

Direction of rotation:CLOCKWISE

Type of arrangement DB Type of arrangement DK

Grouting

h 7

X

A B

s1

h 6h 5

h 4

6B

5D

6B

5

s2

270170

250

a1 a2

1M

DN2 m6

n5

Section A - B

View X

n6

m4

m5

1M

h 2

h 3

Z

DN1

m3

Flanges:- Flat surface flanges- Flange thickness to ANSI- Connect pipes without stress

Connections:- 1M Pressure gauge G 1/2- 5D Vent G 1/2- 6B Drainage G 1/2- 8B Leakage liquid drain G 3/4

Position of the terminal box to be in accordancewith motor dimension sheet

Omega V

76

General arrangement drawing Omega V 250 -- 370 up to 250 -- 600

Major external pump dimensions and weights all dimensions in mm

Pump size Flange dimensions Pump dimensions Weights [kg]DN1 DN2 s1 s2 a1 a2 h2 h3 h4 h5 z 2) Pump Water

content

250-370 33 (51) 1) 32 (48) 1) 500 500300

320 440 1095 640 665 125

250-480 300 25051 48

550550

300 355500 1230

710 830 145

250-60051 48

650550

350 415500 1230

830 1215 180

1) For casing material GGG-NiCrNb 202, JS 1030 1.45172) z = The dimensions to be maintained around the casing cover for dismantling of the rotor

k

d2

numberof holes n

Omega V

77

Standard flange design 1):

Pumpsize

JL 1040 / GGG-NiCrNb 202Nominal pressure acc. to:

JS 1030 / 1.4517Nominal pressure acc. to:

DIN 2501ISO 7005/2

BS 4504 ANSI B 16.1 DIN 2501ISO 7005/2

BS 4504 ANSI B 16.1

250-370 PN 10 Table 10/11 Class 125

250-480 PN 16 Table 16/11Class 250

PN 25 Table 25/11 Class 250

250-600 PN 25 Table 25/11Class 250

1) Other flange designs are available on request

Flange dimensions -- Drilling diagram all dimensions in mm

Standard Suction flange Discharge flange

DN 300 DN 250

d2 k n d2 k n

ISO 7005/2DIN 2501 PN 10 23 400 23 350

ISO 7005/2DIN 2501 PN 16 28 410 12 28 355

ISO 7005/2DIN 2501 PN 25 31 430 16 31 370

12BS 4504 Table 10/11 23 400

1223 350

BS 4504 Table 16/11 28 41012

28 355

BS 4504 Table 25/11 31 430 16 31 370

ANSI B 16.1 Class 125 28 432 1228

362

ANSI B 16.1 Class 250 31 451 1628

387 16

Motor dimensions and weights IEC-Motors, IP 55 2) all dimensions in mm

Pump size Type ofarrangement

Motor size c1 h6 h7 m3 m4 m5 m6 n5 n6 Weightof motor

DB DK [kg]

250 370 �

min. 250 M 550 1240 790 435250-370 � ---- max. 315 L 660 1270 1110

1180 560 6851200

250-480 � ----min. 250 M 550 1375 790 1180 560 685

900435

250-480 � ----max. 355 900 1455

315

900

7002200

� ----min. 315 M 660 1405 970

1210315 700 910

250-600� ----

max. 355 900 14551210

590 7152200

250-600

---- �

min.400 1000 1445 1615 1350

590 715

1260 3200---- �

max.400 1000 1445 1615 1350 1260 3200

2) Dimension and weight deviations subject to selected motor manufacturer are to be considered

Direction of rotation:CLOCKWISE

Type of arrangement DB Type of arrangement DK

Grouting

h 7

X

A B

s1

h 6h 5

h 4

6B

5D

6B

5

s2

270170

250

a1 a2

1M

DN2 m6

n5

Selection A - B

View X

n6

m4

m5

1M

h 2

h 3

Z

DN1

m3

Flanges:- Flat surface flanges- Flange thickness to ANSI- Connect pipes without stress

Connections:- 1M Pressure gauge G 1/2- 5D Vent G 1/2- 6B Drainage G 1/2- 8B Leakage liquid drain G 3/4

Position of the terminal box to be in accordancewith motor dimension sheet

Omega V

78

General arrangement drawing Omega V 300 -- 300 up to 300 -- 700

Major external pump dimensions and weights all dimensions in mmPump size Flange dimensions Pump dimensions Weights [kg]

DN1 DN2 s1 s2 a1 a2 h2 h3 h4 h5 z 2) Pump Watercontent

300-300 350 36 (54) 1)33 (51) 1)

550 500 300 360 440 1095 720 630 100

300-435300

38 (57) 1) 33 (51) 1) 650 550350

365 500 1230 730 905 190

300-560 400 30057 51

700650

350430

570 1380860 1425 225

300-70057 51

750650

400 480570 1380

960 1690 2751) For casing material GGG-NiCrNb 202, JS 1030 1.45172) z = the dimensions to be maintained around the casing cover for dismantling of the rotor

k

d2

numberof holes n

Omega V

79

Standard flange design 1):

Pumpsize

JL 1040 / GGG-NiCrNb 202Nominal pressure acc. to:

JS 1030 / 1.4517Nominal pressure acc. to:

DIN 2501ISO 7005/2

BS 4504 ANSI B 16.1 DIN 2501ISO 7005/2

BS 4504 ANSI B 16.1

300-300PN 10 Table 10/11 Class 125300-435 PN 10 Table 10/11 Class 125

PN 25 Table 25/11 Class 250300-560 PN 16 Table 16/11Class 250

PN 25 Table 25/11 Class 250

300-700 PN 25 Table 25/11Class 250

1) Other flange designs are available on request

Flange dimensions -- Drilling diagram all dimensions in mm

Standard Suction flange Discharge flange

DN 350 DN 400 DN 300

d2 k n d2 k n d2 k n

ISO 7005/2DIN 2501 PN 10 23 460 28 515 23 400

12ISO 7005/2DIN 2501 PN 16 28 470 31 525 28 410

12

ISO 7005/2DIN 2501 PN 25 34 490 16 37 550

1631 430 16

BS 4504 Table 10/11 23 460 28 515 23 40012

BS 4504 Table 16/11 28 470 31 525 28 41012

BS 4504 Table 25/11 34 490 37 550 31 430 16

ANSI B 16.1 Class 125 28 476 12 28 540 28 432 12

ANSI B 16.1 Class 250 31 514 20 34 572 20 31 451 16

Motor Dimensions and weights IEC-Motors, IP 55 2) all dimensions in mm

Pump size Type ofarrangement

Motor size c1 h6 h7 m3 m4 m5 m6 n5 n6 Weightof motor

DB DK [kg]

300 300 �

min. 200 L 400 1210 6651210 590 715

170300-300 � ---- max. 315 S 660 1270 970 1210 590

315715

900 700830

300-435 � ---min. 280 M 550 1375 865

1250 630315

755900 700 660

300-435 � ---max. 315 800 1405 1230

1250 630 7551500

300-560 � ---min. 315 M 660 1555 970

1375 670 795910

300-560 � ---max. 400 1000 1595 1730

1375 670400

7951200 950

3200

300-700 � ----min. 315 800 1555 1230

1415 710400

8351200 950

1500300-700 � ----

max. 400 1000 1615 16151415 710 835

32002) Dimension and weight deviations subject to selected motor manufacturer are to be considered

Direction of rotation:CLOCKWISE”

Type of arrangement DB Type of arrangement DK

Grouting

h 7

X

A B

s1

h 6h 5

h 4

6B

5D

6B

5

s2

270170

250

a1 a2

1M

DN2 m6

n5

Selection A - B

View X

n6

m4

m5

1M

h 2

h 3

Z

DN1

m3

Flanges:- Flat surface flanges- Flange thickness to ANSI- Connect pipes without stress

Connections:- 1M Pressure gauge G 1/2- 5D Vent G 1/2- 6B Drainage G 1/2- 8B Leakage liquid drain G 3/4

Position of the terminal box to be in accordancewith motor dimension sheet

Omega V

80

General arrangement drawing Omega V 350 -- 360 up to 350 -- 510

Major external pump dimensions and weights all dimensions in mmPump size Flange dimensions Pump dimensions Weights [kg]

DN1 DN2 s1 s2 a1 a2 h2 h3 h4 h5 z 2) Pump Watercontent

350-360 400 38 (57) 1) 650 550 350 410 500 1230 820 865 160

350-430 450 350 41 (60) 1) 36 (54) 1) 750 465570 1380

930 1285 240

350-510 400 38 (57) 1) 700 650 400 420570 1380

840 1395 290

1) For casing material GGG-NiCrNb 202, JS 1030 1.45172) z = The dimensions to be maintained around the casing cover for dismantling of the rotor

k

d2

numberof holes n

Omega V

81

Standard flange design 1):

Pumpsize

JL 1040 / GGG-NiCrNb 202Nominal pressure acc. to:

JS 1030 / 1.4517Nominal pressure acc. to:

DIN 2501ISO 7005/2

BS 4504 ANSI B 16.1 DIN 2501ISO 7005/2

BS 4504 ANSI B 16.1

350-360 PN 25

350-430 PN 10 Table 10/11 Class 125 PN 16 Table 25/11 Class 250

350-510 PN 251) Other flange designs are available on request

Flange dimensions -- Drilling diagram all dimensions in mm

Standard Suction flange Discharge flange

DN 400 DN 450 DN 350

d2 k n d2 k n d2 k n

ISO 7005/2DIN 2501 PN 10 28 515 28 565 23 460

ISO 7005/2DIN 2501 PN 16 31 525

1631 585 20 28 470 16

BS 4504 Table 10/11 28 51516

28 565 23 460

BS 4504 Table 16/11 31 52531

58528

470

ANSI B 16.1 Class 125 28 54031

578 1628

476 12

Motor dimensions and weights IEC-Motors, IP 55 2) all dimensions in mm

Pump size Type ofarrangement

Motor size c1 h6 h7 m3 m4 m5 m6 n5 n6 Weightof motor

DB DK [kg]

�

min. 250 M 550 1375 7901250 630 315 755 900 700

435

350-360 � ---- max. 315 800 1405 1230 1250 630 315 755 900 700 1500

� ----min. 315 M 660 1555 940 910

350-430� ----

max. 355 900 1555 14551415 710 400 835 1200 950

2200

� ---min. 315 L 660 1555 1110

1415 710 400 835 1200 9501200

350-510� ---

max. 400 1000 1595 1615 32002) Dimension and weight deviations subject to selected motor manufacturer are to be considered

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82

Lifting device disassembly of uppercasing half and pump rotorDisassembly of upper casing half (105.02) and pump rotor.The lifting device is provided to ensure safe disassembly andreassembly of casing cover and rotor. For safe and experthandling, see opposite figures.The lifting device (figure 1) consists of two elements: thebracket and the fork.

Safety instructions for transport of suspendedloads have to be absolutely observed!

-- To secure the upper casing half (105.02), losen companionbolts of the lower part of the casing and only slightly losenthe companion bolts of the upper part of the casing.

Do not remove the bolts.

-- Suspend the boom in a lifting device and bolt it to the topcasing half using forcing screws (Fig. 2).

-- To support the upper casing half, screw in hexagon bolts asillustrated in figure 2, detail X.

-- Losen cover from the casing with the two upper liftingscrews and remove the remaining companion bolts.

-- Upper casing half and deposit in a safe place.-- For disassembly of the rotor, screw bracket and fork

together.-- Pull apart the coupling halves at the pump side.-- Mount lifting device provided to remove the rotor as

illustrated in figure 3, detail Y, the fork being placedunderneath bearing cover (360).

-- Remove screw (901.04). Next undo nut (920.05) untilbearing casing can be lifted out of the recess.

-- Pull out rotor and deposit it in a safe place until it is furtherdisassembled.

Reassembly-- Reassembly to be made in the reverse order of

disassembly.

Figure 1 Figure 2

Figure 3

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Table of Connections and Measuring Points

5D

6B6B

1M1 1M2

DN2

26M1 4M1

1M1 1M2

X

DN1

26M14M1

View X

Item No. Description Connections Value required

5 D Venting G 1/2

9 D (if applicable) Venting of barrier liquid G 1/2

6 B Casing drain G 1/2

8 B Leakage drain G 3/4 Enter order--specific data !

1 M.1 (if applicable) Pressure gauge connection,suction side

G 1/2 Enter order--specific data !

1 M.2 Pressure gauge connection,discharge side

G 1/2 Enter order--specific data !

4 M.1 (if applicable) Temperature measuring point, bearingDrive end

G 3/8 See section 7.2

26 M.1 (if applicable) Thread for SPM measurement,drive end

M 8 Enter order--specific data !

1. Works No. / Item No.

KRT-F 100-250/7 4 UG-2492--M01--753328

enter here

2. Required part with part No.

enterhere

Sample

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. . . and should something have to be replaced,

KSB’s competent Spare Parts Service is at your disposal for the products

D Amarex/KRT D Amamix/AmapropD Sewatec D AmajetD Amacan D GetecD Omega

To: KSB Aktiengesellschaft Postfach 200743 Date:Turmstr. 92 D-06008 Halle/SaaleD-06110 Halle/SaaleErsatzteilabteilung

Fax: (+49) 345/48 26 4691 Tel: (+49) 345/48 26--0

From:

In order to ensure the smooth processing of your spare parts inquiry, we request that you let us have the following data:

D The works No. is given on the name plateof your pumpe.g. 2--M01--753328

or9970428626 000100 2

in addition:

Pump typee.g. KRT-F 100-250/7 4 UG-249

D The description of the parts is givenin the operating instructionse.g. Impeller, Part no. 230

in addition:

for multi--vane impeller:impeller diameter in mm

for terminal gland:cable length in mm

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KSB AktiengesellschaftP.O. Box 200743 � 06008 Halle (Saale) � Turmstraße 92 � 06110 Halle (Germany)Tel. +49 (345) 48 26 0 � Fax +49 (345) 48 26 46 99 � www.ksb.com

1384.81--10

12/2004

Subjecttomodificationwithoutnotice

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